Oilfield device with wireless telemetry

ABSTRACT

An acoustic control system wirelessly operates a subsea latching assembly or other subsea device, such as an active seal. The acoustic control system may control a subsea first accumulator to release its stored hydraulic fluid to operate the latch assembly or other subsea device, such as an active seal. An RCD or other oilfield device may be unlatched or latched with the latching assembly. The acoustic control system may have a surface control unit, a subsea control unit, and two or more acoustic signal devices. A valve may allow switching from an umbilical line system to the acoustic control system accumulator.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 12/643,093 filed Dec. 21, 2009, which claims the benefit of U.S. Provisional Application No. 61/205,209 filed Jan. 15, 2009, which are hereby incorporated by reference for all purposes in their entirety.

This application claims the benefit of U.S. Provisional Application No. 61/394,155 filed on Oct. 18, 2010, which is hereby incorporated by reference for all purposes in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

REFERENCE TO MICROFICHE APPENDIX

N/A

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to subsea drilling, and in particular to a system and method for unlatching and/or latching a rotating control device (RCD) or other oilfield device.

2. Description of Related Art

Marine risers extending from a wellhead fixed on the floor of an ocean have been used to circulate drilling fluid back to a structure or rig. An example of a marine riser and some of the associated drilling components is proposed in U.S. Pat. Nos. 4,626,135 and 7,258,171. RCDs have been proposed to be positioned with marine risers. U.S. Pat. No. 6,913,092 proposes a seal housing with a RCD positioned above sea level on the upper section of a marine riser to facilitate a mechanically controlled pressurized system. U.S. Pat. No. 7,237,623 proposes a method for drilling from a floating structure using an RCD positioned on a marine riser. U.S. Pat. Nos. 6,470,975, 7,159,669; and 7,258,171 propose positioning an RCD assembly in a housing disposed in a marine riser. In the '171 patent, the system for drilling in the floor of an ocean uses a RCD with a bearing assembly and a holding member for removably positioning the bearing assembly in a subsea housing. Also, an RCD has also been proposed in U.S. Pat. No. 6,138,774 to be positioned subsea without a marine riser.

More recently, the advantages of using underbalanced drilling, particularly in mature geological deepwater environments, have become known. RCD's, such as disclosed in U.S. Pat. No. 5,662,181, have provided a dependable seal between a rotating pipe and the riser while drilling operations are being conducted. U.S. Pat. No. 6,138,774 proposes the use of a RCD for overbalanced drilling of a borehole through subsea geological formations. U.S. Pat. No. 6,263,982 proposes an underbalanced drilling concept of using a RCD to seal a marine riser while drilling in the floor of an ocean from a floating structure. Additionally, U.S. Provisional Application No. 60/122,350, filed Mar. 2, 1999, entitled “Concepts for the Application of Rotating Control Head Technology to Deepwater Drilling Operations” proposes use of a RCD in deepwater drilling. U.S. Pat. No. 4,813,495 proposes a subsea RCD as an alternative to the conventional drilling system and method when used in conjunction with a subsea pump that returns the drilling fluid to a drilling vessel.

Conventional RCD assemblies have been sealed with a subsea housing using active sealing mechanisms in the subsea housing. Pub. No. US 2010/0175882 proposes a mechanically extrudable seal or a hydraulically expanded seal to seal the RCD with the riser. Additionally, conventional RCD assemblies, such as proposed by U.S. Pat. No. 6,230,824, have used powered latching mechanisms in the subsea housing to position the RCD. U.S. Pat. No. 7,487,837 proposes a latch assembly for use with a riser for positioning an RCD. U.S. Pat. No. 7,836,946 B2 proposes a latching system to latch an RCD to a housing and active seals. U.S. Pat. No. 7,926,593 proposes a docking station housing positioned above the surface of the water for latching with an RCD. Pub. No. US 2009/0139724 proposes a latch position indicator system for remotely determining whether a latch assembly is latched or unlatched.

U.S. Pat. No. 6,129,152 proposes a flexible rotating bladder and seal assembly that is hydraulically latchable with its rotating blow-out preventer housing. U.S. Pat. No. 6,457,529 proposes a circumferential ring that forces dogs outward to releasably attach an RCD with a manifold. U.S. Pat. No. 7,040,394 proposes inflatable bladders/seals. U.S. Pat. No. 7,080,685 proposes a rotatable packer that may be latchingly removed independently of the bearings and other non-rotating portions of the RCD. The '685 patent also proposes the use of an indicator pin urged by a piston to indicate the position of the piston.

Latching assemblies for RCDs have been proposed to be operated subsea with an electro-hydraulic umbilical line from the surface. A remotely operated vehicle (ROV) and a human diver have also been proposed to operate the latching assemblies. However, an umbilical line may become damaged. It is also possible for sea depths and/or conditions to be unsafe and/or impractical for a diver or a ROV. In such situations, the marine riser may have to be removed to extract the RCD.

U.S. Pat. No. 3,405,387 proposes an acoustical control apparatus for controlling the operation of underwater valve equipment from the surface. U.S. Pat. No. 4,065,747 proposes an apparatus for transmitting command or control signals to underwater equipment. U.S. Pat. No. 7,123,162 proposes a subsea communication system for communicating with an apparatus at the seabed. Pub. No. US 2007/0173957 proposes a modular cable unit positioned subsea for the attachment of devices such as sensors and motors.

The above discussed U.S. Pat. Nos. 3,405,387; 4,065,747; 4,626,135; 4,813,495; 5,662,181; 6,129,152; 6,138,774; 6,230,824; 6,263,982; 6,457,529; 6,470,975; 6,913,092; 7,040,394; 7,080,685; 7,123,162; 7,159,669; 7,237,623; 7,258.171; 7,487,837; 7,836,946 B2; and 7,926,593 and Pub. Nos. US 2007/0173957; 2009/0139724; and 2010/0175882; and U.S. Provisional Application No. 60/122,350, filed Mar. 2, 1999, entitled “Concepts for the Application of Rotating Control Head Technology to Deepwater Drilling Operations” are all hereby incorporated by reference for all purposes in their entirety.

It would be desirable to have a system and method to unlatch an RCD or other oilfield device from a subsea latching assembly when the umbilical line primarily responsible for operating the latching assembly is damaged or use of the umbilical line is impractical or not desirable, and using a diver or an ROV may be unsafe or impractical.

BRIEF SUMMARY OF THE INVENTION

An acoustic control system may remotely operate a subsea latch assembly. In one embodiment, the acoustic control system may control a subsea first accumulator storing hydraulic fluid. The hydraulic fluid may be pressurized. The first accumulator may be remotely and/or manually charged and purged. In response to an acoustic signal, the first accumulator may release its fluid to operate the subsea latching assembly. The released fluid may move a piston in the latching assembly to unlatch an RCD or other oilfield device. The latching assembly may be disposed with a marine riser and/or a subsea wellhead if there is no marine riser. If there is a marine riser, the latching assembly may be disposed below the tension lines or tension ring supporting the top of the riser from the drilling structure or rig.

The acoustic control system may have a surface control unit, a subsea control unit, and two or more acoustic signal devices. One of the acoustic signal devices may be capable of transmitting an acoustic signal, and the other acoustic signal device may be capable of receiving the acoustic signal. In one embodiment, acoustic signal devices may be transceivers connected with transducers each capable of transmitting and receiving acoustic signals between each other to provide for two-way communication between the surface control unit and the subsea control unit. The subsea control unit may control the first accumulator.

A second accumulator or a compensator may be used to capture hydraulic fluid moving out of the latching system to prevent its escape into the environment. The acoustic control system may be used as a secondary or back-up system in case of damage to the primary electro-hydraulic umbilical line, or it may be used as the primary system for operating the latching assembly. In one embodiment, one or more valves or a valve pack may be disposed with the accumulators and the umbilical line to switch to the secondary acoustic control system as needed.

In other embodiments, the acoustic control system may be used to both latch and/or unlatch the RCD or other oilfield device with the subsea housing or marine riser, including by moving primary and/or secondary pistons within the latch assembly. In another embodiment, the system may be used to operate active seals to retain and/or release a RCD or other oilfield device disposed with a subsea housing or marine riser.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the present invention can be obtained with the following detailed descriptions of the various disclosed embodiments in the drawings, which are given by way of illustration only, and thus are not limiting the invention, and wherein:

FIG. 1 is a cross-sectional elevational view of an RCD having two passive seals and latched with a riser spool or housing having two latching members shown in the latched position and an active packer seal shown in the unsealed position.

FIG. 1A is a section view along stepped line 1A-1A of FIG. 1 showing second retainer member as a plurality of dogs in the latched position, a plurality of vertical grooves on the outside surface of the RCD, and a plurality of fluid passageways between the dogs and the RCD.

FIG. 2 is a cross-sectional elevational view of an RCD with three passive seals latched with a riser spool or housing having two latching members shown in the latched position, an active seal shown in the unsealed position, and a bypass channel or line having a valve therein.

FIG. 3A is a cross-sectional elevational partial view of an RCD having a seal assembly disposed with an RCD running tool and latched with a riser spool or housing having two latching members shown in the latched position and an active seal shown in the sealed position.

FIG. 3B is a section view along line 3B-3B of FIG. 3A showing an ROV panel and an exemplary placement of lines, such as choke lines, kill lines, booster lines, umbilical lines and/or other lines, cables and conduits around the riser spool.

FIGS. 4A-4B are a cross-sectional elevational view of an RCD with three passive seals having a seal assembly disposed with an RCD running tool and latched with a riser spool or housing having three latching members shown in the latched position, the lower latch member engaging the seal assembly, and a bypass conduit or line having a valve therein.

FIGS. 5A-5B are a cross-sectional elevational view of an RCD with three passive seals having a seal assembly disposed with an RCD running tool and sealed with a riser housing and the RCD latched with the riser housing having two latching members shown in the latched position and a bypass conduit or line having a valve therein.

FIG. 6A is a cross-sectional elevational partial view of an RCD having a seal assembly with a mechanically extrudable seal assembly seal shown in the unsealed position, the seal assembly having two unsheared shear pins and a ratchet shear ring.

FIG. 6B is a cross-sectional elevational partial broken view of the RCD of FIG. 6A with the RCD running tool moved downward from its position in FIG. 6A to shear the seal assembly upper shear pin and ratchet the ratchet shear ring to extrude the seal assembly seal to the sealed position.

FIG. 6C is a cross-sectional elevational partial broken view of the RCD of FIG. 6B with the RCD running tool moved upward from its position in FIG. 6B, the seal assembly upper shear pin sheared but in its unsheared position, the ratchet shear ring sheared to allow the seal assembly seal to move to the unsealed position, and the riser spool or housing latching members shown in the unlatched position.

FIG. 7A is a cross-sectional elevational partial view of an RCD having a seal assembly with a seal assembly seal shown in the unsealed position, the seal assembly having upper, intermediate, and lower shear pins, a unidirectional ratchet or lock ring, and two concentric split C-rings.

FIG. 7B is a cross-sectional elevational partial broken view of the RCD of FIG. 7A with the RCD running tool moved downward from its position in FIG. 7A, the seal assembly upper shear pin and lower shear pin shown sheared and the ratchet ring ratched to extrude the seal assembly seal to the sealed position.

FIG. 7C is a cross-sectional elevational partial broken view of the RCD of FIG. 7B with the RCD running tool moved upward from its position in FIG. 7B, the seal assembly upper shear pin and lower shear pin sheared but in their unsheared positions, the intermediate shear pin sheared to allow the seal assembly seal to move to the unsealed position while all the riser spool or housing latching members remain in the latched position.

FIG. 8A is a cross-sectional elevational partial split view of an RCD having a seal assembly with a seal assembly seal shown in the unsealed position and a RCD seal assembly loss motion connection latched with a riser spool or housing, on the right side of the break line an upper shear pin and a lower shear pin disposed with an RCD running tool both unsheared, and on the left side of the break line, the RCD running tool moved upward from its position on the right side of the break line to shear the lower shear pin.

FIG. 8B is a cross-sectional elevational partial broken view of the RCD of FIG. 8A with the RCD running tool moved upward from its position on the left side of the break line in FIG. 8A, the lower latch member retainer moved to the lower end of the loss motion connection and the unidirectional ratchet ring ratcheted upwardly to extrude the seal assembly seal.

FIG. 8C is a cross-sectional elevational partial broken view of the RCD of FIG. 8B with the RCD running tool moved downward from its position in FIG. 8B, the seal assembly seal in the sealed position and the radially outward split C-ring moved from its concentric position to its shouldered position.

FIG. 8D is a cross-sectional elevational partial broken view of the RCD of FIG. 8C with the RCD running tool moved upward from its position in FIG. 8C so that a running tool shoulder engages the racially inward split C-ring.

FIG. 8E is a cross-sectional elevational partial broken view of the RCD of FIG. 8D with the RCD running tool moved further upward from its position in FIG. 8D so that the shouldered C-rings shear the upper shear pin to allow the seal assembly seal to move to the unsealed position after the two upper latch members are unlatched.

FIG. 9A is a cross-sectional elevational partial view of an RCD having a seal assembly with a seal assembly seal shown in the unsealed position, a seal assembly latching member in the latched position, upper, intermediate and lower shear pins, all unsheared, and an upper and a lower unidirectional ratchet or lock rings, the RCD seal assembly disposed with an RCD running tool, and latched with a riser spool having three latching members shown in the latched position and a bypass conduit or line.

FIG. 9B is a cross-sectional elevational partial broken view of the RCD of FIG. 9A with the RCD running tool moved downward from its position in FIG. 9A, the upper shear pin sheared and the lower ratchet ring ratcheted to extrude the seal assembly seal.

FIG. 9C is a cross-sectional elevational partial broken view of the RCD of FIG. 9B with the RCD running tool moved downward from its position in FIG. 9B, the lower shear pin sheared, and the seal assembly seal to the sealed position and the radially outward garter springed segments moved from their concentric position to their shouldered position.

FIG. 9D is a cross-sectional elevational partial broken view of the RCD of FIG. 9C with the RCD running tool moved upward from its position in FIG. 9C so that the shouldered garter spring segments shear the intermediate shear pin to allow the seal assembly dog to move to the unlatched position after the two upper latch members are unlatched.

FIG. 9E is a cross-sectional elevational partial broken view of the RCD of FIG. 9D with the RCD running tool moved further upward from its position in FIG. 9D, the lower shear pin sheared but in its unsheared position, the seal assembly dog in the unlatched position to allow the seal assembly seal to move to the unsealed position after the two upper latch members are unlatched.

FIG. 10A is a cross-sectional elevational partial view of an RCD having a seal assembly, similar to FIG. 4B, with the seal assembly seal shown in the unsealed position, a seal assembly dog shown in the latched position, unsheared upper and lower shear pins, and a unidirectional ratchet or lock ring, the lower shear pin disposed between an RCD running tool and garter springed segments, and a riser spool having three latching members shown in the latched position and a bypass conduit or line.

FIG. 10B is a cross-sectional elevational partial broken view of the RCD of FIG. 10A with the RCD running tool moved upward from its position in FIG. 10A, the RCD seal assembly loss motion connection receiving the lower latch member retainer and the lower shear pin sheared to allow the lower garter springed segments to move inwardly in a slot on the running tool.

FIG. 10C is a cross-sectional elevational partial broken view of the RCD of FIG. 10B with the RCD running tool moved downward after it had moved further upward from its position in FIG. 10B to move the lower latch member retainer to the lower end of the loss motion connection and the unidirectional ratchet or lock ring maintaining the seal assembly seal in the sealed position and to move the upper garter springed segments from their concentric position to their shouldered position.

FIG. 10D is a cross-sectional elevational partial broken view of the RCD of FIG. 10C with the RCD running tool moved upward from its position in FIG. 10C after running down hole, so the shouldered garter spring segments shear the upper shear pin while the seal assembly seal is maintained in the sealed position after the two upper latch members are unlatched.

FIG. 10E is a cross-sectional elevational partial broken view of the RCD of FIG. 10D with the RCD running tool moved further upward from its position in FIG. 10D so the seal assembly dog can move to its unlatched position to allow the seal assembly seal to move to the unsealed position after the two upper latch members are unlatched.

FIG. 11 is a cross-sectional elevational view of an RCD disposed with a single hydraulic latch assembly.

FIG. 12 is a cross-sectional elevational view of an RCD disposed with a dual hydraulic latch assembly.

FIG. 13 is an elevational view of an RCD latched with a latching assembly (not shown) in a housing with a first umbilical line on the left side extending from a first umbilical line reel and connected with the housing, and a second umbilical line on the right side extending from a second umbilical line reel and attached with a valve pack (not shown) connected to accumulators, with a signal device in a stowed position below the accumulators.

FIG. 14 is a schematic view of an acoustic control system including a surface control unit, a subsea control unit, a first acoustic signal device supported below sea level from a reel, and second and third acoustic signal devices shown in exploded view disposed with a valve pack and a plurality of subsea accumulators positioned with a subsea housing having an internal latching assembly.

FIG. 15 is a schematic view of the accumulators and valve pack of FIG. 14 disposed with hydraulic lines, check valves, and sensors.

FIG. 16 is a schematic view of the acoustic control system of FIGS. 14 and 15 with the valve pack and accumulators disposed with a semi-submersible floating rig positioned with a marine riser and BOP stack over a wellhead in elevational view.

FIG. 17 is a cross-sectional elevational view of an RCD disposed with a subsea housing allowing drilling with no marine riser.

FIG. 18 is a cross-sectional elevational view of an RCD disposed with a subsea housing over a subsea BOP stack allowing drilling with no marine riser.

FIG. 19 is an elevational view of an RCD in phantom view latchable with a housing, with accumulators releaseably coupled with the housing with an accumulator clamp ring, and a signal device disposed below the accumulators in a stowed position.

FIG. 20 is the same as FIG. 19 except with the signal device in a deployed position.

FIG. 21 is the same as FIG. 19 except with the housing rotated 90 degrees about a vertical axis to show three operating accumulators and one receiving accumulator or compensator.

FIG. 22 is a plan view of FIG. 21 with the four accumulators attached with the housing with an accumulator clamp ring, and with the signal device moved from a stowed position, in phantom view, to a deployed position.

FIG. 23A is a schematic view of the accumulators and valve pack of FIG. 14 disposed with hydraulic lines, check valves, and sensors.

FIG. 23B is a schematic view of the accumulators and valve pack of FIG. 14 disposed with hydraulic lines, check valves, and sensors.

DETAILED DESCRIPTION OF THE INVENTION

Generally, a system and method for unlatching and/or latching an RCD or other oilfield device positioned with a latching assembly is disclosed. Also, a system and method for sealing and/or unsealing an RCD or other oilfield device using an active seal is disclosed. The latching assembly may be disposed with a marine riser and/or subsea housing. If there is a marine riser, it is contemplated that the latching assembly be disposed below the tension lines or tension ring supporting the top of the riser from the drilling structure or rig. An RCD may have an inner member rotatable relative to an outer member about thrust and axial bearings, such as RCD Model 7875, available from Weatherford International of Houston, Tex., and other RCDs proposed in the '181, '171 and '774 patents. Although certain RCD types and sizes are shown in the embodiments, other RCD types and sizes are contemplated for all embodiments, including RCDs with different numbers, configurations and orientations of passive seals, and/or RCDs with one or more active seals. It is also contemplated that the system and method may be used to operate these active seals.

In FIG. 1, riser spool or housing 12 is positioned with marine riser sections (4, 10). Marine riser sections (4, 10) are part of a marine riser, such as disclosed above in the Background of the Invention. Housing 12 is illustrated bolted with bolts (24, 26) to respective marine riser sections (4, 10). Other attachment means are contemplated. An RCD 2 with two passive stripper seals (6, 8) is landed in and latched to housing 12 using latching assemblies, such as first latching piston 14 and second latching piston 18, both of which may be actuated, such as described in the '837 patent (see FIGS. 2 and 3 of '837 patent). Active packer seal 22 in housing 12, shown in its noninflated and unsealed position, may be hydraulically expandable to a sealed position to sealingly engage the outside diameter of RCD 2 using the present invention.

Remote Operated Vehicle (ROV) subsea control panel 28 may be positioned with housing 12 between protective flanges (30, 32) for operation of hydraulic latching pistons (14, 18) and active packer seal 22. An ROV 3 containing hydraulic fluid may be sent below sea level to connect with the ROV panel 28 to control operations the housing 12 components. The ROV 3 may be controlled remotely from the surface. In particular, by supplying hydraulic fluid to different components using shutter valves and other mechanical devices, latching pistons (14, 18) and active seal 22 may be operated when practical. Alternatively, or in addition for redundancy, one or more hydraulic lines, such as umbilical line 5, may be run from the surface to supply hydraulic fluid for remote operation of the housing 12 latching pistons (14, 18) and active seal 22. Alternatively, or in addition for further redundancy and safety, an accumulator 7 for storing hydraulic fluid may be activated remotely to operate the housing 12 components or store fluids under pressure. It is contemplated that all three means for hydraulic fluid could be provided. It is also contemplated that a similar ROV panel, ROV, hydraulic lines, and/or accumulator may be used with all embodiments of the invention.

The RCD 2 outside diameter is smaller than the housing 12 inside diameter or straight thru bore. First retainer member 16 and second retainer member 20 are shown in FIG. 1 after having been moved from their respective first or unlatched positions to their respective second or latched positions. RCD 2 may have a change in outside diameter that occurs at first retainer member 16. As shown in FIG. 1, the upper outside diameter 9 of RCD 2 may be greater than the lower outside diameter 31 of RCD 2. Other RCD outside surface configurations are contemplated, including the RCD not having a change in outside diameter.

As shown in FIGS. 1 and 1A, the RCD 2 upper outside diameter 9 above the second retainer member 20 and between the first 16 and second 20 retainer members may have a plurality of vertical grooves 23. As shown in FIG. 1A, second retainer member 20 may be a plurality of dogs. First retainer member 16 may also be a plurality of dogs like second retainer member 20. Retainer members (16, 20) may be segmented locking dogs. Retainer members (16, 20) may each be a split ring or C-shaped member, or they may each be a plurality of segments of split ring or C-shaped members. Retainer members (16, 20) may be biased radially outwardly. Retainer members (16, 20) may each be mechanical interlocking members, such as tongue and groove type or T-slide type, for positive retraction. Other retainer member configurations are contemplated.

The vertical grooves 23 along the outside surface of RCD 2 allow for fluid passageways 25 when dogs 20 are in the latched position as shown in FIG. 1A. The vertical grooves 23 allow for the movement of fluids around the RCD 2 when the RCD 2 is moved in the riser. The vertical grooves 23 are provided to prevent the compression or surging of fluids in the riser below the RCD 2 when RCD 2 is lowered or landed in the riser and swabbing or a vacuum effect when the RCD 2 is raised or retrieved from the riser.

Returning to FIG. 1, first retainer member 16 blocks the downward movement of the RCD 2 during landing by contacting RCD blocking shoulder 11, resulting from the change between upper RCD outside diameter 9 and lower RCD outside diameter 31. Second retainer member 20 has engaged the RCD 2 in a horizontal radial receiving groove 33 around the upper outside diameter 9 of RCD 2 to squeeze or compress the RCD 2 between retainer members (16, 20) to resist rotation. In their second or latched positions, retainer members (16, 20) also may squeeze or compress RCD 2 radially inwardly. It is contemplated that retainer members (16, 20) may be alternatively moved to their latched positions radially inwardly and axially upwardly to squeeze or compress the RCD 2 using retainer members (16, 20) to resist rotation. As can now be understood, the RCD may be squeezed or compressed axially upwardly and downwardly and radially inwardly. In their first or unlatched positions, retainer members (16, 20) allow clearance between the RCD 2 and housing 12. In their second or latched positions, retainer members (16, 20) block and latchingly engage the RCD 2, respectively, to resist vertical movement and rotation. The embodiment shown in FIGS. 1 and 1A for the outside surface of the RCD 2 may be used for all embodiments shown in all the Figures.

While it is contemplated that housing 12 may have a 10,000 psi body pressure rating, other pressure ratings are contemplated. Also, while it is contemplated that the opposed housing flanges (30, 32) may have a 39 inch (99.1 cm) outside diameter, other sizes are contemplated. RCD 2 may be latchingly attached with a 21.250 inch (54 cm) thru bore 34 of marine riser sections (4, 10) with a 19.25 (48.9 cm) inch inside bore 12A of housing 12. Other sizes are contemplated. It is also contemplated that housing 12 may be positioned above or be integral with a marine diverter, such as a 59 inch (149.9 cm) inside diameter marine diverter. Other sizes are contemplated. The diverter will allow fluid moving down the drill pipe and up the annulus to flow out the diverter opening below the lower stripper seal 8 and the same active seal 22. Although active seal 22 is shown below the bearing assembly of the RCD 2 and below latching pistons (14, 18), it is contemplated that active seal 22 may be positioned above the RCD bearing assembly and latching pistons (14, 18). It is also contemplated that there may be active seals both above and below the RCD bearing assembly and latching pistons (14, 18). All types of seals, active or passive, as are known in the art are contemplated. While the active seal 22 is illustrated positioned with the housing 12, it is contemplated that the seal, active or passive, could instead be positioned with the outer surface of the RCD 2.

In the method, to establish a landing for RCD 2, which may be an 18.00 inch (45.7 cm) outer diameter RCD, the first retainer member 16 is remotely activated to the latched or loading position. The RCD 2 is then moved into the housing 12 until the RCD 2 lands with the RCD blocking shoulder 11 contacting the first retainer member 16. The second retainer member 20 is then remotely activated with hydraulic fluid supplied as discussed above to the latched position to engage the RCD receiving groove 33, thereby creating a clamping force on the RCD 2 outer surface to, among other benefits, resist torque or rotation. In particular, the top chamfer on first retainer member 16 is engaged with the RCD shoulder 11. When the bottom chamfer on the second retainer member 20 moves into receiving groove 33 on the RCD 2 outer surface, the bottom chamfer “squeezes” the RCD between the two retainer members (16, 20) to apply a squeezing force on the RCD 2 to resist torque or rotation. The active seal 22 may then be expanded with hydraulic fluid supplied as discussed herein to seal against the RCD 2 lower outer surface to seal the gap or annulus between the RCD 2 and the housing 12.

The operations of the housing 12 may be controlled remotely through the ROV fluid supplied to the control panel 28, with hydraulic line 5 and/or accumulator 7. Other methods are contemplated, including activating the second retainer member 20 simultaneously with the active seal 22. Although a bypass channel or line, such as an internal bypass channel 68 shown in FIG. 2 and an external bypass line 186 shown in FIG. 4A, is not shown in FIG. 1, it is contemplated that a similar external bypass line or internal bypass channel with a valve may be used in FIG. 1 or in any other embodiment herein. The operation of a bypass line with a valve is discussed in detail below with FIG. 2.

Back-up or secondary pistons (1000, 1002) may move respective primary pistons (14, 18) to their unlatched positions should the hydraulic system fail to move primary pistons (14, 18). Secondary pistons (1000, 1002) may operate independently of each other.

Turning to FIG. 2, an RCD 40 with three passive stripper seals (41, 46, 48) is positioned with riser spool or housing 72 with first retainer member 56 and second retainer member 60, both of which are activated by respective hydraulic pistons in respective latching assemblies (54, 58). First retainer member 56 blocks movement of the RCD 40 when blocking shoulder 43 engages retainer member 56 and second retainer member 60 is positioned with RCD receiving formation or groove 45. The operations of the housing 72 components may be controlled remotely using ROV 61 connected with ROV control panel 62 positioned between flanges (74, 76) and further protected by shielding member 64. Alternatively, or in addition, as discussed above, housing 74 components may be operated by hydraulic lines and/or accumulators. RCD stripper seal 41 is inverted from the other stripper seals (46, 48) to, among other reasons, resist “suck down” of drilling fluids during a total or partial loss circulation. Such a loss circulation could result in the collapse of the riser if no fluids were in the riser to counteract the outside forces on the riser. For RCD 40 in FIG. 2, and for similar RCD stripper seal embodiments in the other Figures, it is contemplated that the two opposing stripper seals, such as stripper seals (41, 46), may be one integral or continuous seal rather than two separate seals.

The RCD 40 outside diameter is smaller than the housing 72 inside diameter, which may be 19.25 inches (48.9 cm). Other sizes are contemplated. While the riser housing 72 may have a 10.000 psi body pressure rating, other pressure ratings are contemplated. Retainer members (56, 60) may be a plurality of dogs or a C-shaped member, although other types of members are contemplated. Active seal 66, shown in an unexpanded or unsealed position, may be expanded to sealingly engage RCD 40 using the present invention. Alternatively, or in addition, an active seal may be positioned above the RCD bearing assembly and latching assemblies (54, 58). Housing 74 is illustrated bolted with bolts (50, 52) to marine riser sections (42, 44). As discussed above, other attachment means are contemplated. While it is contemplated that the opposed housing flanges (74, 76) may have a 45 inch (114.3 cm) outside diameter, other sizes are contemplated. As can now be understood, the RCD 40 may be latchingly attached with the thru bore of housing 72. It is also contemplated that housing 74 may be positioned with a 59 inch (149.9 cm) inside diameter marine diverter.

The system shown in FIG. 2 is generally similar to the system shown in FIG. 1, except for internal bypass channel 68, which, as stated above, may be used with any of the embodiments. Valve 78, such as a gate valve, may be positioned in bypass channel 68. Two end plugs 70 may be used after internal bypass channel 68 is manufactured, such as shown in FIG. 2, to seal communication with atmospheric pressure outside the wellbore. Bypass channel 68 with gate valve 78 acts as a check valve in well kick or blowout conditions. Gate valve 78 may be operated remotely. For example, if hazardous weather conditions are forecasted, the valve 78 could be closed with the riser sealable controlled and the offshore rig moved to a safer location. Also, if the riser is raised with the RCD in place, valve 78 could be opened to allow fluid to bypass the RCD 40 and out the riser below the housing 72 and RCD 40. In such conditions, fluid may be allowed to flow through bypass channel 68, around RCD 40, via bypass channel first end 80 and bypass channel second end 82, thereby bypassing the RCD 40 sealed with housing 72. Alternatively to internal bypass channel 68, it is contemplated that an external bypass line, such as bypass line 186 in FIG. 4A, may be used with FIG. 2 and any other embodiments.

In FIG. 3A, riser spool or housing 98 is illustrated connected with threaded shafts and nuts 116 to marine riser section 100. An RCD 90 having a seal assembly 92 is positioned with an RCD running tool 94 with housing 98. Seal assembly latching formations 118 may be positioned in the J-hook receiving grooves 96 in RCD running tool 94 so that the running tool 94 and RCD 90 are moved together on the drill string through the marine riser and housing 98. Other attachment means are contemplated as are known in the art. A running tool, such as running tool 94, may be used to position an RCD with any riser spool or housing embodiments. RCD 90 is landed with housing 98 with first retainer member 106 and squeezed with second retainer member 110, both of which are remotely actuated by respective hydraulic pistons in respective latching assemblies (104, 108). First retainer member 106 blocks RCD shoulder 105 and second retainer member 110 is positioned with RCD second receiving formation or groove 107.

ROV control panel 114 may be positioned with housing 98 between upper and lower shielding protrusions 112 (only lower protrusion shown) to protect the panel 114. Other shielding means are contemplated. While it is contemplated that the opposed housing flanges 120 (only lower flange shown) of housing 98 may have a 45 inch (114.3 cm) outside diameter, other sizes are contemplated. The RCD 90 outside diameter is smaller than the housing 98 inside diameter. Retainer members (106, 110) may be a plurality of dogs or a C-shaped member. Active seal 102, shown in an expanded or sealed position, sealingly engages RCD 102. After the RCD 90 is sealed as shown in FIG. 3A, the running tool 94 may be disengaged from the RCD seal assembly 92 and continue moving with the drill string down the riser for drilling operations. Alternatively, or in addition, an active or passive seal may be positioned on RCD 90 instead of on housing 98, and/or may be positioned both above and below RCD bearing assembly or latching assemblies (104, 108). Alternatively to the embodiment shown in FIG. 3A, a seal assembly, such as seal assembly 92, may be positioned above the RCD bearing assembly or latching assemblies (104, 108) to engage an RCD running tool. The alternative seal assembly may be used to either house a seal, such as seal 102, or be used as the portion of the RCD to be sealed by a seal in a housing, similar to the embodiment shown in FIG. 3A.

Generally, lines and cables extend radially outwardly from the riser, as shown in FIG. 1 of the '171 patent, and male and female members of the lines and cables can be plugged together as the riser sections are joined together. Turning to FIG. 3B, an exemplary rerouting or placement of these lines and cables is shown external to housing 98 within the design criteria inside diameter 130 as the lines and cables traverse across the housing 98. Exemplary lines and cables may include 1.875 inch OD multiplex cables 134, 2.375×2.000 rigid conduit lines 136, a 5.563×4.5 mud boost line 138, a 7×4.5 kill line 140, a 7×4.5 choke line 142, a 7.5×6 mud return line 144, and a 7.5×6 seawater fluid power line 146. Other sizes, lines (such as the discussed umbilical lines) and cables and configurations are contemplated. It is also contemplated that an ROV or accumulator(s) may be used to replace some of the lines and/or conduits.

It is contemplated that a marine riser segment would stab the male or pin end of its riser tubular segment lines and cables with the female or box end of a lower riser tubular segment lines and cables. The lines and cables, such as shown in FIG. 3B, may also be stabbed or plugged with riser tubular segment lines and cables extending radially outward so that they may be plugged together when connecting the riser segments. In other words, the lines and/or cables shown in FIG. 3B are rerouted along the vertical elevation profile exterior to housing 98 to avoid housing protrusions, such as panel 114 and protrusion 112, but the lines and cables are aligned radially outward to allow them to be connected with their respective lines and cables from the adjoining riser segments. Although section 3B-3B is only shown with FIG. 3A, similar exemplary placement of the ROV panel, lines, and cables as shown in FIG. 3B may be used with any of the embodiments.

An external bypass line 186 with gate valve 188 is shown and discussed below with FIG. 4A. Although FIG. 3A does not show a bypass line and gate valve, it is contemplated that the embodiment in FIG. 3A may have a bypass line and gate valve. FIG. 3B shows an exemplary placement of a gate valve 141 with actuator 143 if used with FIG. 3A. A similar placement may be used for the embodiment in FIG. 4A and other embodiments.

In FIGS. 4A-4B, riser spools or housings (152A, 152B) are bolted between marine riser sections (154, 158) with respective bolts (156, 160). Housing 152A is bolted with housing 152B using bolts 157. A protection member 161 may be positioned with one or more of the bolts 157 (e.g., three openings in the protection member to receive three bolts) to protect an ROV panel, which is not shown. An RCD 150 with three passive stripper seals (162, 164, 168) is positioned with riser spools or housings (152A, 152B) with first retainer member 172, second retainer member 176, and third retainer member or seal assembly retainer 182 all of which are activated by respective hydraulic pistons in their respective latching assemblies (170, 174, 180). Retainer members (172, 176, 182) in housing 152B as shown in FIG. 4B have been moved from their respective first or unlatched positions to their respective second or latched positions. First retainer member 172 blocks RCD shoulder 173 and second retainer member 176 is positioned with RCD receiving formation or groove 175. The operations of the housing 152B may be controlled remotely using in any combination an ROV connected with an ROV containing hydraulic fluid and control panel, hydraulic lines, and/or accumulators, all of which have been previously described but not shown for clarity of the Figure.

The RCD seal assembly, generally indicated at 178, for RCD 150 and the RCD running tool 184 are similar to the seal assembly and running tool shown in FIGS. 10A-10E and are described in detail below with those Figures. RCD stripper seal 162 is inverted from the other stripper seals (164, 168). Although RCD seal assembly 178 is shown below the RCD bearing assembly and below the first and second latching assemblies (170, 174), a seal assembly may alternatively be positioned above the RCD bearing assembly and the first and second latching assemblies (170, 174) for all embodiments.

External bypass line 186 with valve 188 may be attached with housing 152 with bolts (192, 196). Other attachment means are contemplated. A similar bypass line and valve may be positioned with any embodiment. Unlike bypass channel 68 in FIG. 2, bypass line 186 in FIGS. 4A-4B is external to and releasable from the housings (152A. 152B). Bypass line 186 with gate valve 188 acts as a check valve in well kick or blowout conditions. Gate valve 188 may be operated remotely. Also, if hazardous weather conditions are forecasted, the valve 188 could be closed with the riser sealable controlled and the offshore rig moved to a safer location.

Also, when the riser is raised with the RCD in place, valve 188 could be opened to allow fluid to bypass the RCD 150 and out the riser below the housing 152B and RCD 150. In such conditions when seal assembly extrudable seal 198 is in a sealing position (as described below in detail with FIGS. 10A-10E), fluid may be allowed to flow through bypass line 186, around RCD 150, via bypass line first end 190 and bypass line second end 194, thereby bypassing RCD 150 sealed with housing 152B. Alternatively to external bypass line 186, it is contemplated that an internal bypass channel, such as bypass channel 68 in FIG. 2, may be used with FIGS. 4A-4B and any other embodiment.

Turning to FIGS. 5A-5B, riser spool or housing 202 is illustrated bolted to marine riser sections (204, 208) with respective bolts (206, 210). An RCD 200 having three passive seals (240, 242, 244) and a seal assembly 212 is positioned with an RCD running tool 216 used for positioning the RCD 200 with housing 202. Seal assembly latching formations 214 may be positioned in the J-hook receiving grooves 218 in RCD running tool 216 and the running tool 216 and RCD 200 moved together on the drill string through the marine riser. RCD 200 is landed with housing 202 with first retainer member 222 and latched with second retainer member 226, both of which are remotely actuated by respective hydraulic pistons in respective latching assemblies (220, 224). First retainer member 222 blocks RCD shoulder 223 and second retainer member 226 is positioned with RCD receiving formation or groove 225.

Upper 202A, intermediate 202B, and lower 202C active packer seals may be activated using the present invention to seal the annulus between the housing 202 and RCD 200. Upper seal 202A and lower active seal 202C may be sealed together to protect latching assemblies (220, 224). Intermediate active seal 202B may provide further division or redundancy for seal 202C. It is also contemplated that lower active seal 202C may be sealed first to seal off the pressure in the riser below the lower seal 202C. Upper active seal 202A may then be sealed at a pressure to act as a wiper to resist debris and trash from contacting latching members (220, 224). Other methods are contemplated. Sensors (219, 229, 237) may be positioned with housing 202 between the seals (202A. 202B, 202C) to detect wellbore parameters, such as pressure, temperature, and/or flow. Such measurements may be useful in determining the effectiveness of the seals (202A, 202B, 202C), and may indicate if a seal (202A, 202B, 202C) is not sealing properly or has been damaged or failed.

It is also contemplated that other sensors may be used to determine the relative difference in rotational speed (RPM) between any of the RCD passive seals (240, 242, 244), for example, seals 240 and 242. For the embodiment shown in FIGS. 5A-5B, as well as all other embodiments, a data information gathering system, such as DIGS, provided by Weatherford may be used with a PLC to monitor and/or reduce relative slippage of the sealing elements (240, 242, 244) with the drill string. It is contemplated that real time revolutions per minute (RPM) of the sealing elements (240, 242, 244) may be measured. If one of the sealing elements (240, 242, 244) is on an independent inner member and is turning at a different rate than another sealing element (240, 242, 244), then it may indicate slippage of one of the sealing elements with tubular. Also, the rotation rate of the sealing elements can be compared to the drill string measured at the top drive (not shown) or at the rotary table in the drilling floor.

The information from all sensors, including sensors (219, 229, 237), may be transmitted to the surface for processing with a CPU through an electrical line or cable positioned with hydraulic line 5 shown in FIG. 1. An ROV may also be used to access the information at ROV panel 228 for processing either at the surface or by the ROV. Other methods are contemplated, including remote accessing of the information. After the RCD 200 is latched and sealed as shown in FIG. 5B, the running tool 216 may be disengaged from the RCD 200 and continue moving with the drill string down the riser for drilling operations.

ROV control panel 228 may be positioned with housing 200 between two shielding protrusions 230 to protect the panel 228. The RCD 200 outside diameter is smaller than the housing 202 inside diameter. Retainer members (222, 226) may be a plurality of dogs or a C-shaped member. External bypass line 232 with valve 238 may be attached with housing 202 with bolts (234, 236). Other attachment means are contemplated. Bypass line 232 with gate valve 238 acts as a check valve in well kick or blowout conditions. Valve 238 may be operated remotely.

Turning to FIG. 6A, RCD 250 having a seal assembly, generally designated at 286, is shown latched in riser spool or housing 252 with first retainer member 256, second retainer member 260, and third retainer member or seal assembly retainer 264 of respective latching assemblies (254, 258, 262) in their respective second or latched/landed positions. First retainer member 256 blocks RCD shoulder 257 and second retainer member 260 is positioned with RCD receiving formation or groove 259. An external bypass line 272 is positioned with housing 252. An ROV panel 266 is disposed with housing 252 between two shielding protrusions 268. Seal assembly 286 comprises RCD extension or extending member 278, tool member 274, retainer receiving member 288, seal assembly seal 276, upper or first shear pins 282, lower or second shear pins 280, and ratchet shear ring or ratchet shear 284. Although two upper 282 and two lower 280 shear pins are shown for this and other embodiments, it is contemplated that there may be only one upper 282 and one lower 280 shear pin or that there may be a plurality of upper 282 and lower 280 shear pins of different sizes, metallurgy and shear rating. Other mechanical shearing devices as are known in the art are also contemplated.

Seal assembly seal 276 may be bonded with tool member blocking shoulder 290 and retainer receiving member 288, such as by epoxy. A lip retainer formation in either or both the tool member 274 and retainer receiving member 288 that fits with a corresponding formation(s) in seal 276 is contemplated. This retainer formation, similar to formation 320 shown and/or described with FIG. 7A, allows seal 276 to be connected with the tool member 274 and/or retainer receiving member 288. A combination of bonding and mechanical attachment as described above may be used. Other attachment methods are contemplated. The attachment means shown and discussed for use with extrudable seal 276 may be used with any extrudable seal shown in any embodiment.

Extrudable seal 276 in FIG. 6A, as well as all similar extrudable seals shown in all RCD sealing assemblies in all embodiments, may be made from one integral or monolithic piece of material, or alternatively, it may be made from two or more segments of different materials that are formed together with structural supports, such as wire mesh or metal supports. The different segments of material may have different properties. For example, if the seal 276 were made in three segments of elastomers, such as an upper, intermediate, and lower segment when viewed in elevational cross section, the upper and lower segments may have certain properties to enhance their ability to sandwich or compress a more extrudable intermediate segment. The intermediate segment may be formed differently or have different properties that allow it to extrude laterally when compressed to better seal with the riser housing. Other combinations and materials are contemplated.

Seal assembly 286 is positioned with RCD running tool 270 with lower shear pins 280 and running tool shoulder 271. After the running tool is made up in the drill string, the running tool 270 and RCD 250 are moved together from the surface down through the marine riser to housing 252 in the landing position shown in FIG. 6A. In one method, it is contemplated that before the RCD 250 is lowered into the housing 252, first retainer member 256 would be in the landing position, and second 260 and third 264 retainer members would be in their unlatched positions. RCD shoulder 257 would contact first retainer member 256, which would block downward movement. Second retainer member 260 would then be moved to its latched position engaging RCD receiving formation 259, which, as discussed above, would squeeze the RCD between the first 256 and second 260 retaining members to resist rotation. Third retaining member would then be moved to its latched position with retainer receiving member 288, as shown in FIG. 6A. After landing, the seal assembly seal 276 may be extruded as shown in FIG. 6B. It should be understood that the downward movement of the running tool and RCD may be accomplished using the weight of the drill string. For all embodiments of the invention shown in all the Figures, it is contemplated that a latch position indicator system, such as one of the embodiments proposed in the '837 patent or the '724 publication, may be used to determine whether the latching pistons, such as latching assemblies (254, 258, 262) of FIG. 6A, are in their latched or unlatched positions. It is contemplated that a programmable logic controller (PLC) having a comparator may compare hydraulic fluid values or parameters to determine the positions of the latches. It is also contemplated that an electrical switch system, a mechanical valve system and/or a proximity sensor system may be positioned with a retainer member. Other methods are contemplated.

It is contemplated that seal assembly 286 may be detachable from RCD 250, such as at locations (277A, 277B). Other attachment locations are contemplated. Seal assembly 286 may be threadingly attached with RCD 250 at locations (277A, 277B). Other types of connections are contemplated. The releasable seal assembly 286 may be removed for repair, and/or for replacement with a different seal assembly. It is contemplated that the replacement seal assembly would accommodate the same vertical distance between the first retainer member 256, the second retainer member 260 and the third retainer member 264. All seal assemblies in all the other embodiments in the Figures may similarly be detached from their RCD.

FIG. 6B shows the setting position used to set or extrude seal assembly seal 276 to seal with housing 252. To set the extrudable seal 276, the running tool 270 is moved downward from the landing position shown in FIG. 6A. This downward motion shears the upper shear pin 282 but not the lower shear pin 280. This downward movement also ratchets the ratchet shear ring 284 upwardly. As can now be understood, lower shear pin 280 has a higher shear and ratchet force than upper shear pin 282 and ratchet shear ring 284, respectively, relative to retainer receiving member 288 and then maintains the relative position. Therefore, ratchet shear ring 284 allows the downward movement of the tool member 274. The running tool 270 pulls the tool member 274 downward. It is contemplated that the force needed to fully extrude seal 276 is less than the shear strength of upper shear pin 282.

When upper shear pin 282 is sheared, there is sufficient force to fully extrude seal 276. Tool member 274 will move downward after upper shear pin 282 is sheared. Tool member blocking shoulder 292 prevents further downward movement of the tool member 274 when shoulder 292 contacts the upward facing blocking shoulder 294 of RCD extending member 278. However, it is contemplated that the seal 276 will be fully extruded before tool member 274 blocking shoulder 292 contacts upward facing shoulder 294. Ratchet shear ring 284 prevents tool member 274 from moving back upwards after tool member 274 moves downwards.

Shoulder 290 of tool member 274 compresses and extrudes seal 276 against retainer receiving member 288, which is held fixed by third retainer member 264. During setting, ratchet shear ring 284 allows tool member 274 to ratchet downward with minimal resistance and without shearing the ring 284. After the seal 276 is set as shown in FIG. 6B, running tool 270 may continue downward through the riser for drilling operations by shearing the lower shear pin 280. Ratchet shear ring 284 maintains tool member 274 from moving upward after the lower shear pin 280 is sheared, thereby keeping seal assembly seal 276 extruded as shown in FIG. 6B during drilling operations. As can now be understood, for the embodiment shown in FIGS. 6A-6C, the weight of the drill string moves the running tool 270 downward for setting the seal assembly seal 276.

As shown in the FIG. 6B view, it is contemplated that shoulder 290 of tool member 274 may be sloped with a positive slope to enhance the extrusion and sealing of seal 276 with housing 252 in the sealed position. It is also contemplated that the upper edge of retainer receiving member 288 that may be bonded with seal 276 may have a negative slope to enhance the extrusion and sealing of seal 276 in the sealed position with housing 252. The above described sloping of members adjacent to the extrudable seal may be used with all embodiments having an extrudable seal. For FIG. 6A and other embodiments with extrudable seals, it is contemplated that if the distance between the outer facing surface of the unextruded seal 276 as it is shown in FIG. 6A, and the riser housing 252 inner bore surface where the extruded seal 276 makes contact when extruded is 0.75 inch (1.91 cm) to 1 inch (2.54 cm), then 2000 to 3000 of sealing force could be provided. Other distances or gaps and sealing forces are contemplated. It should be understood that the greater the distance or gap, the lower the sealing force of the seal 276. It should also be understood that the material composition of the extrudable seal will also affect its sealing force.

FIG. 6C shows the housing 252 in the fully released position for removal or retrieval of the RCD 250 from the housing 252. After drilling operations are completed, the running tool 270 may be moved upward through the riser toward the housing 252. When running tool shoulder 271 makes contact with tool member 274, as shown in FIG. 6C, first, second and third retainer members (256, 260, 264) should be in their latched positions, as shown in FIGS. 6A and 6B. Running tool shoulder 271 then pushes tool member 274 upward, shearing the teeth of ratchet shear ring 284. As can now be understood, ratchet shear ring 284 allows ratcheting in one direction, but shears when moved in the opposite direction upon application of a sufficient force. Tool member 274 moves upward until upwardly facing blocking shoulder 296 of tool member 274 contacts downwardly facing blocking shoulder 298 of extending member 278. The pin openings used to hold the upper 282 and lower 280 shear pins should be at substantially the same elevation before the pins were sheared. FIG. 6C shows the sheared upper 282 and lower 280 shear pins being aligned. Again, the pins could be continuous in the pin opening or equidistantly spaced as desired and depending on the pin being used.

When tool member 274 moves upward, tool member blocking shoulder 290 moves upward, pulling seal assembly seal 276 relative to fixed retainer receiving member 288 retained by the third retainer member 264 in the latched position. The seal 276 is preferably stretched to substantially its initial shape, as shown in FIG. 6C. The retainer members (256, 260, 264) may then be moved to their first or unlatched positions as shown in FIG. 6C, and the RCD 250 and running tool 270 removed together upward from the housing 252.

Turning to FIG. 7A, RCD 300 and its seal assembly, generally designated 340, are shown latched in riser spool or housing 302 with first retainer member 304, second retainer member 308, and third retainer member or seal assembly retainer 324 of respective latching pistons (306, 310, 322) in their respective second or latched/landed positions. First retainer member 304 blocks RCD shoulder 342 and second retainer member 308 is positioned with RCD second receiving formation 344. An external bypass line 346 is positioned with housing 302. An ROV panel 348 is disposed with housing 302 between a shielding protrusion 350 and flange 302A. Seal assembly 340 comprises RCD extending member 312, RCD tool member 314, tool member 330, retainer receiving member 326, seal assembly seal 318, upper shear pins 316, intermediate shear pins 332, lower shear pins 334, ratchet or lock ring 328, inner split C-ring 352, and outer split C-ring 354. Inner C-ring 352 has shoulder 358. Tool member 314 has downwardly facing blocking shoulders (368, 360). Tool member 330 has upwardly facing blocking shoulders 362 and downwardly facing blocking shoulder 364. Retainer receiving member 326 has downwardly facing blocking shoulder 366. Extending member 312 has downwardly facing blocking shoulder 370.

Although two upper 316, two lower 334 and two intermediate 332 shear pins are shown, it is contemplated that there may be only one upper 316, one lower 334 and one intermediate 332 shear pin or, as discussed above, that there may be a plurality of upper 316, lower 334 and intermediate 332 shear pins. Other mechanical shearing devices as are known in the art are also contemplated. Seal assembly seal 318 may be bonded with RCD tool member 314 and retainer receiving member 326, such as by epoxy. A lip retainer formation 320 in RCD tool member 314 fits with a corresponding formation in seal 318 to allow seal 318 to be pulled by RCD tool member 314. Although not shown, a similar lip formation may be used to connect the seal 318 with retainer receiving member 326. A combination of bonding and mechanical attachment as described above may be used.

Seal assembly 340 is positioned with RCD running tool 336 with lower shear pins 334, running tool shoulder 356, and concentric C-rings (352, 354). The running tool 336 and RCD 300 are moved together from the surface through the marine riser down into housing 302 in the landing position shown in FIG. 7A. In one method, it is contemplated that before the RCD 300 is lowered into the housing 302, first retainer member 304 would be in the landed position, and second 308 and third 324 retainer members would be in their unlatched positions. RCD shoulder 342 would be blocked by first retainer member 304 to block the downward movement of the RCD 300. Second retainer member 308 would then be moved to its latched position engaging RCD receiving formation 344, which would squeeze the RCD between the first 304 and second 308 retaining members to resist rotation. Third retaining member 324 would then be moved to its latched position with retainer receiving member 326 as shown in FIGS. 7A-7C. After landing is completed, the seal assembly seal 318 may be set or extruded.

FIG. 7B shows the setting position used to set or extrude seal assembly seal 318 with housing 302. To set the extrudable seal 318, the running tool 336 is moved downward from the landing position shown in FIG. 7A so that the shoulder 365 of running tool 336 pushes the inner C-ring 352 downward. Inner C-ring 352 contacts blocking shoulder 362 of tool member 330, and pushes the tool member 330 down until the blocking shoulder 364 of the tool member 330 contacts the blocking shoulder 366 of retainer receiving member 326, as shown in FIG. 7B. Outer C-ring 354 then moves inward into groove 358 of inner C-ring 352 as shown in FIG. 7B. The downward motion of the running tool 336 first shears the lower shear pins 334, and after inner C-ring 352 urges tool member 330 downward, the upper shear pins 316 are sheared, as shown in FIG. 7B. The intermediate shear pins 332 are not sheared. As can now be understood, the intermediate shear pins 332 have a higher shear strength than the upper shear pins 316 and lower shear pins 334. The intermediate shear pin 332 pulls RCD tool member 314 downward until downwardly facing blocking shoulder 368 of RCD tool member 314 contacts upwardly facing blocking shoulder 370 of RCD extending member 312. The ratchet or lock ring 328 allows the downward ratcheting of tool member 330 relative to retainer receiving member 326. Like ratchet shear ring 284 of FIGS. 6A-6C, ratchet or lock ring 328 of FIGS. 7A-7C allows ratcheting. However, unlike ratchet shear ring 284 of FIGS. 6A-6C, ratchet or lock ring 328 of FIGS. 7A-7C is not designed to shear when tool member 330 moves upwards, but rather ratchet or lock ring 328 resists the upward movement of the adjacent member to maintain the relative positions.

Shoulder 360 of RCD tool member 314 compresses and extrudes seal 318 against retainer receiving member 326, which is fixed by third retainer member 324. After the seal 318 is set as shown in FIG. 7B, running tool 336 may continue downward through the riser for drilling operations. Ratchet or lock ring 328 and intermediate shear pin 332 prevent tool member 330 and RCD tool member 314 from moving upwards, thereby maintaining seal assembly seal 318 extruded as shown in FIG. 7B during drilling operations. As can now be understood, for the embodiment shown in FIGS. 7A-7C, the running tool 336 is moved downward for setting the seal assembly seal 318 and pulled to release. The weight of the drill string may be relied upon for the downward force.

FIG. 7C shows the running tool 336 moved up in the housing 302 after drilling operations for unsetting the seal 318 and thereafter retrieving the RCD 300 from the housing 302. Running tool shoulder 370 makes contact with inner C-ring 352. First, second and third retainer members (304, 308, 324) are in their latched positions, as shown for first 304 and third 324 retainer members in FIG. 7C. Inner C-ring 352 shoulders with outer C-ring 354, outer C-ring 354 shoulders with RCD tool member 314 to shear intermediate shear pins 332. Ratchet or lock ring 328 maintains tool member 330. As can now be understood, ratchet or lock ring 328 allows movement of tool member 330, in one direction, but resists movement in the opposite direction. RCD tool member 314 moves upward until blocking shoulder 361 of RCD tool member 314 contacts blocking shoulder 371 of extending member 312. The openings used to hold the upper 316 and lower 334 shear pins should be at substantially the same elevation before the pins were started.

When RCD tool member 314 moves upward, RCD tool member blocking shoulder 360 moves upward, pulling seal assembly seal 318 with lip retainer formation 320 and/or the bonded connection since retainer receiving member 326 is fixed by the third retainer member 324 in the latched position. The retainer members (304, 308, 324) may then be moved to their first or unlatched positions, and the RCD 300 and running tool 336 together pulled upwards from the housing 302.

Turning to FIG. 8A, RCD 380 and its seal assembly, generally indicated 436, are shown latched in riser spool or housing 382 with first retainer member 386, second retainer member 390, and third retainer member or seal assembly retainer 398 of respective latching pistons (388, 392, 400) in their respective second or latched positions. First retainer member 386 blocks RCD shoulder 438 and second retainer member 390 is positioned with RCD receiving formation 440. An external bypass line 384 is positioned with housing 382. A valve may be positioned with line 384 and any additional bypass line. An ROV panel 394 is disposed with housing 382 between a shielding protrusion 396 and a protection member 381 positioned with flange 382A, similar to protection member 161 in FIG. 4A. Returning to FIG. 8A, seal assembly 436 comprises RCD extending member 402, tool member 418, retainer receiving member 416, seal assembly seal 404, upper shear pins 422, lower shear pins 408, ratchet lock ring 420, lower shear pin retainer ring or third C-ring 410, inner or first C-ring 428, and outer or second C-ring 430. Inner C-ring 428 has groove 432 for seating outer C-ring 430 when running tool 412 is moved downward from its position shown on the left side of the break line in FIG. 8A, as will be described in detail with FIG. 8C. Tool member 418 has blocking shoulder 426. Retainer receiving member 416 has blocking shoulder 424 and loss motion connection or groove 434 for a loss motion connection with third retainer member 398 in its latched position, as shown in FIG. 8A. Extending member 402 has a lip retainer formation 406 for positioning with a corresponding formation on seal 404.

Although two upper 422 and two lower 408 shear pins are shown for this embodiment, it is contemplated that there may be only one upper 422 and one lower 408 shear pin or, as discussed above, that there may be a plurality of upper 422 and lower 408 shear pins for this embodiment of the invention. Other mechanical shearing devices as are known in the art are also contemplated. Seal assembly seal 404 may be bonded with extending member 402 and retainer receiving member 416, such as by epoxy. A lip retainer formation 406 in RCD extending member 402 fits with a corresponding formation in seal 404 to allow seal 404 to be pulled by extending member 402. Although not shown, a similar lip formation may be used to connect the seal 404 with retainer receiving member 416. A combination of bonding and mechanical attachment as described above may be used. Other attachment methods are contemplated.

Seal assembly 436 is positioned with RCD running tool 412 with lower shear pins 408 and third C-ring 410, running tool shoulder 414, and concentric inner and outer C-rings (428, 430). The running tool 412 and RCD 380 are moved together from the surface through the marine riser down into housing 382 in the position landing shown on the right side of the break line in FIG. 8A. In one method, it is contemplated that before the RCD 380 is lowered into the housing 382, first retainer member 386 would be in the latched or landing position, and second 390 and third 398 retainer members would be in their unlatched positions. RCD shoulder 438 would contact first retainer member 386, which would block the downward movement of the RCD 380. Second retainer member 390 would then be moved to its latched position engaging RCD receiving formation 440 to squeeze the RCD 380 between the first retaining members 386 and second retaining members 390 to resist rotation. Third retaining member 398 would then be moved to its latched position with retainer receiving member 416, as shown in FIG. 8A.

On the left side of the break line in FIG. 8A, the running tool 412 has moved upwards, shearing the lower shear pins 408. Shoulder 426 of tool member 418 pushes lower shear pin retainer C-ring 410 downward to slot 413 of running tool 412. C-ring 410 has an inward bias and contracted inward from its position shown on the right side of the break line due to the diameter of the running tool 413. Blocking shoulder 414 of running tool 412 has made contact with blocking shoulder 424 of retainer receiving member 416.

FIG. 8B shows the setting position to mechanically set or extrude seal assembly seal 404 with housing 382. To set the extrudable seal 404, the running tool 412 is moved upward from the landing position, shown on the right side of FIG. 8A, to the position shown on the left side of FIG. 8A. The blocking shoulder 414 of running tool 412 pushes the retainer receiving member 416 upward. Loss motion groove 434 of retainer receiving member 416 allows retainer receiving member 416 to move upward until it is blocked by downwardly facing blocking shoulder 426 of tool member 418 and the upward facing shoulder 427 of retainer receiving member 46 as shown in FIG. 8C. The ratchet or lock ring 420 allows upward ratcheting of retainer receiving member 416 with tool member 418. It should be understood that the tool member 418 does not move downwards to set the seal 404 in FIG. 8C. Like the ratchet or lock ring 328 of FIGS. 7A-7C, ratchet or lock ring 420 maintains the positions of its respective members.

Retainer receiving member 416 compresses and extrudes seal 404 against RCD extending member 402, which is latched with held by first retainer member 386. After the seal 404 is set as shown in FIG. 8B, running tool 412 may begin moving downward as shown in FIG. 8C through the riser for drilling operations. Ratchet or lock ring 420 maintains retainer receiving member 416 from moving downwards, thereby keeping seal assembly seal 404 extruded as shown in FIG. 8B during drilling operations. As can now be understood, for the embodiment shown in FIGS. 8A-8E, unlike the embodiments shown in FIGS. 6A-6C and 7A-7C, the running tool 412 is moved upwards for extruding the seal assembly seal 404.

In FIG. 8C, the running tool 412 has begun moving down through the housing 382 from its position in FIG. 8B to begin drilling operations after seal 404 has been extruded. RCD 380 remains latched with housing 382. Running tool shoulder 440 makes contact with inner C-ring 428 pushing it downwards. Outer C-ring 430, which has a radially inward bias, moves from its concentric position inward into groove 432 in inner C-ring 428, and inner C-ring 428 moves outward enough to allow running tool shoulder 440 to move downward past inner C-ring 428. Running tool may then move downward with the drill string for drilling operations.

FIG. 8D shows RCD running tool 412 returning from drilling operations and moving upwards into housing 382 for the RCD 380 retrieval process. Shoulder 442 of running tool 412 shoulders inner C-ring 428, as shown in FIG. 8D. FIG. 8E shows the seal assembly 436 and housing 382 in the RCD retrieval position. The first retainer members 386 and second retainer members 390 are in their first or unlatched positions. Running tool 412 moves upwards and running tool shoulder 442 shoulders inner C-ring 428 upwards, which shoulders outer C-ring 430. Outer C-ring 430 then shoulders unlatched RCD extending member 402 upwards. RCD 380 having RCD extending member 402 may move upwards since first 386 and second 390 retainer members are unlatched. Lip formation 406 of extending member 402 pulls seal 404 upwards. Seal 404 may also be bonded with extending member 402. Retainer receiving member 416 remains shouldered against third retainer 398 in the latched position. It is contemplated that seal 404 may also be bonded with retainer receiving member 416, and/or may also have a lip formation connection similar to formation 406 on extending member 402. In all embodiments of the invention, when retrieving or releasing an RCD from the housing, the running tool is pulled or moves upwards into the housing.

Turning to FIG. 9A, RCD 444 and its seal assembly 466 are shown latched in riser spool or housing 446 with first retainer member 448, second retainer member 452, and third retainer member or seal assembly retainer member 462 of respective latching pistons (450, 454, 464) in their respective second or latched positions. First retainer member 448 blocks RCD shoulder 492 and second retainer member 452 is positioned with RCD receiving formation 494. An external bypass line 456 is positioned with housing 446. An ROV panel 458 is disposed with housing 446 between a shouldering protrusion 460 and flange 446A. Seal assembly 466 comprises RCD or extending member 470, RCD tool member 490, tool member 482, retainer receiving member 496, seal member 476, seal assembly seal 480, upper shear pins 472, intermediate shear pins 474, lower shear pins 484, seal assembly dog 478, upper lock ring ratchet or lock ring 488, lower ratchet or lock ring 486, inner or first C-ring 498, and outer segments 500 with two garter springs 502. It is contemplated that there may be a plurality of segments 500 held together radially around inner C-ring 498 by garter springs 502. Segments 500 with garter springs 502 are a radially enlargeable member urged to be contracted radially inward. It is also contemplated that there may be only one garter spring 502 or a plurality of garter springs 502. It is also contemplated that an outer C-ring may be used instead of outer segments 500 with garter springs 502. An outer C-ring may also be used with garter springs. Inner C-ring 498 is disposed between running tool shoulders (518, 520). Inner C-ring 498 has groove 504 for seating outer segments 500 when running tool 468 is moved downward from its position in FIG. 9A, as will be described in detail with FIG. 9C.

Upper ratchet or lock ring 488 is disposed in groove 524 of RCD extending member 470. Although two upper 472, two lower 484 and two intermediate 474 shear pins are shown for this embodiment, it is contemplated that there may be only one upper shear pin 472, one lower shear pin 484 and one intermediate sheer pin 474 shear pin or, as discussed above, that there may be a plurality of upper 472, lower 484 and intermediate 474 shear pins. Other mechanical shearing devices as are known in the art are also contemplated. Seal assembly seal 480 may be bonded with seal member 476 and retainer receiving member 496, such as by epoxy. A lip retainer formation 506 in seal member 476 fits with a corresponding formation in seal 480 to allow seal 480 to be pulled by seal member 476, as will be described below in detail with FIG. 9E. Although not shown, a similar lip formation may be used to connect the seal 480 with retainer receiving member 496. A combination of bonding and mechanical attachment, as described above, may be used. Other attachment methods are contemplated.

Seal assembly, generally indicated as 466, is positioned with RCD running tool 468 with lower shear pins 484, running tool shoulder 508, inner C-ring 498, and segments 500 with garter springs 502. The running tool 468 and RCD 444 are moved together from the surface through the marine riser down into housing 446 in the landing position shown in FIG. 9A. In one method, it is contemplated that before the RCD 444 is lowered into the housing 446, first retainer member 448 would be in the landing position, and second 452 and third 462 retainer members would be in their unlatched positions. RCD shoulder 492 would contact first retainer member 448 to block the downward movement of the RCD 444. Second retainer member 452 would then be moved to its latched position engaging RCD receiving formation 494, which would squeeze the RCD between the first 448 and second 452 retaining members to resist rotation. Third retaining member 462 would then be moved to its latched position with retainer receiving member 496 as shown in FIG. 9A.

FIG. 9B shows the first stage of the setting position used to mechanically set or extrude seal assembly seal 480 with housing 446. To set the extrudable seal 480, the running tool 468 is moved downward from the landing position shown in FIG. 9A. The lower shear pin 484 pulls tool member 482 downward with running tool 468. Tool member shoulder 518 also shoulders inner C-ring 498 downward relative to outer segments 500 held with garter springs 502. Similar to ratchet or lock ring 328 of FIGS. 7A-7C, lower ratchet or lock ring 486 allows the downward movement of tool member 482 while resisting the upward movement of the tool member 482. Similarly, upper ratchet or lock ring 488 allows the downward movement of RCD tool member 490 while resisting the upward movement of the RCD tool member 490. However, as will be discussed below with FIG. 9D, upper ratchet or lock ring 488 is positioned in slot 524 of extending member 470, allowing movement of upper ratchet or lock ring 488.

RCD tool member 490 is pulled downward by intermediate shear pins 474 disposed with tool member 482. The downward movement of tool member 482 shears upper shear pins 472. As can now be understood, the shear strength of upper shear pins 472 is lower than the shear strengths of intermediate shear pins 474 and lower shear pins 484 shear pins. Tool member 482 moves downward until its downwardly facing blocking shoulder 514 contacts retainer receiving member upwardly facing blocking shoulder 516. Seal assembly retaining dog 478 pulls seal member 476 downward until its downwardly facing shoulder 510 contacts extending member upwardly facing shoulder 512. Dog 478 may be a C-ring with radially inward bias. Other devices are contemplated. Seal assembly retainer 462 is latched, fixing retainer receiving member 496. Seal assembly seal 480 is extruded or set as shown in FIG. 9B. Lower ratchet or lock ring 486 resists tool member 482 from moving upwards, and dog 478 resists seal member 476 from moving upwards, thereby maintaining seal assembly seal 480 extruded as shown in FIG. 9B during drilling operations.

FIG. 9C shows the final stage of setting the seal 480. Running tool 468 is moved downward from its position in FIG. 9B using the weight of the drill string to shear lower shear pin 484. As can now be understood, lower shear pin 484 has a lower shear strength than intermediate shear pin 474. RCD running tool shoulder 518 pushes inner C-ring 498 downward and outer segments 500 may move inward into groove 504 of inner C-ring 498, as shown in FIG. 9C. Running tool 468 may then proceed downward with the drill string for drilling operations, leaving RCD 444 sealed with the housing 446. As can now be understood, for the embodiment shown in FIGS. 9A-9E, the running tool 468 is moved downward for setting the seal assembly seal 480. The weight of the drill string may be relied upon for the downward force.

FIG. 9D shows the running tool 468 moving up in the housing 446 after drilling operations for the first stage of unsetting or releasing the seal 480 and thereafter retrieving the RCD 444 from the housing 446. Running tool shoulder 520 shoulders inner C-ring 498. Third retainer member 462 is in its latched position. Inner C-ring 498 shoulders outer segments 500 upwards by the shoulder in groove 504, and outer segments 500 shoulders RCD tool member 490 upwards, shearing intermediate shear pins 474. Upper ratchet or lock ring 488 moves upwards in slot 524 of RCD extending member 470 until it is blocked by shoulder 526 of extending member 470. Seal assembly retainer dog 478 is allowed to move inwardly or retracts into slot 522 of RCD tool member 490. Although not shown in FIGS. 9D-9E, first 448 retainer member and second retainer member 452, shown in FIG. 9A, are moved into their first or unlatched positions. It is also contemplated that both or either of first retainer member 448 and second retainer member 452 may be moved to their unlatched positions before the movement of the running tool 468 shown in FIG. 9D.

Turning to FIG. 9E, the final stage for unsealing seal 480 is shown. Running tool 468 is moved upwards from its position in FIG. 9D, and running tool shoulder 520 shoulders inner C-ring 498 upwards. Inner C-ring 498 shoulders outer segments 500 disposed in slot 504 of inner C-ring 498 upwards. Outer segments 500 shoulders RCD tool member 490 upwards. Since upper ratchet or lock ring 488 had previously contacted shoulder 526 of extension member 470 in FIG. 9D, upper ratchet or ring 488 now shoulders RCD extending member 470 upwards by pushing on shoulder 526. RCD extending member 470 may move upwards with RCD 444 since first retaining member 448 and second retaining member 452 are in their unlatched positions. Upwardly facing shoulder 512 of extending member 470 pulls downwardly facing shoulder 510 of seal member 476 upwards, and seal member 476, in turn, stretches seal 480 upwards through lip formation 506 and/or bonding with seal 480.

Third retainer member 462 maintains retainer receiving member 496 and the one end of seal 480 fixed, since seal 480 is bonded and/or mechanically attached with retainer receiving member 496. Seal assembly retainer dog 478 moves along slot 522 of RCD tool member 490. Seal 480 is preferably stretched to substantially its initial shape, as shown in FIG. 9E, at which time the openings in running tool 468 and tool member 482 for holding lower shear pins 484, which was previously sheared, are at the same elevation when the lower shear pin 484 was not sheared. Seal assembly retainer member or third retainer member 462 may then be moved to its first or unlatched position, allowing RCD running tool 468 to lift the RCD 444 to the surface.

Turning to FIG. 10A, RCD 530 and its seal assembly 548 are shown latched in riser spool or housing 532 with first retainer member 536, second retainer member 540, and third retainer member 544 of respective latching pistons (538, 542, 546) in their respective second or latched positions. First retainer member 536 blocks RCD shoulder 582 and second retainer member 540 is positioned with RCD receiving formation 584. An external bypass line 534 is positioned with housing 532. Seal assembly, generally indicated at 548, comprises RCD extending member 550, RCD tool member 580, tool member 560, retainer receiving member 554, seal assembly seal 570, upper shear pins 578, lower shear pins 558, lower shear pin holding segments 556 with garter springs 586, ratchet or lock ring 562, inner C-ring 564, outer segments 566 with garter springs 568, and seal assembly retaining dog 576. It is contemplated that C-rings may be used instead of segments (566, 556) with respective garter springs (568, 586), or that C-rings may be used with garter springs. Tool member shoulder 600 shoulders with lower shear pin segments 556. Inner C-ring 564 has groove 572 for seating outer segments 566 when running tool 552 is moved as described with and shown in FIG. 10C. Inner C-ring 562 shoulders with running tool shoulder 588. Retainer receiving member 554 has a blocking shoulder 590 in the loss motion connection or groove 592 for a loss motion connection with third retainer member 544 in its latched position, as shown in FIG. 10A.

Although two upper shear pins 578 and two lower shear pins 558 are shown, it is contemplated that there may be only one upper shear pin 578 and one lower shear pin 558 or, as discussed above, that there may be a plurality of upper shear pins 578 and lower shear pins 558. Other mechanical shearing devices as are known in the art are also contemplated. Seal assembly seal 570 may be bonded with extending member 550 and retainer receiving member 554, such as by epoxy. A lip retainer formation 574 in RCD extending member 550 fits with a corresponding formation in seal 570 to allow seal 570 to be pulled by extending member 550. Although not shown, a similar lip formation may be used to connect the seal 570 with retainer receiving member 554. A combination of bonding and mechanical attachment as described above may be used. Other attachment methods are contemplated.

Seal assembly, generally indicated at 548, is positioned with RCD running tool 552 with lower shear pins 558 and lower shear pin segments 556, running tool shoulder 588, inner C-ring 564, and outer segments 566 with garter springs 568. Lower shear pin segments 556 are disposed on running tool surface 594, which has a larger diameter than adjacent running tool slot 596. The running tool 552 and RCD 530 are moved together from the surface through the marine riser down into housing 532 in the landing position shown in FIG. 10A. In one method, it is contemplated that before the RCD 530 is lowered into the housing 532, first retainer member 536 would be in the landing position, and second 540 and third 544 retainer members would be in their unlatched positions. RCD shoulder 582 would be blocked by first retainer member 536, which would block downward movement of the RCD 530. Second retainer member 540 would then be moved to its latched position engaging RCD receiving formation 584, which would squeeze the RCD 530 between the first 536 and second 540 retaining members to resist rotation. Third retaining member 544 would then be moved to its latched position with retainer receiving member 554 in loss motion connection or groove 592 as shown in FIG. 10A. After landing is completed, the process of extruding the seal assembly seal 570 may begin as shown in FIGS. 10B-10C.

In FIG. 10B, the running tool 552 has moved upwards, and blocking shoulder 600 of tool member 560 has pushed lower shear pin holding segments 556 downward from running tool surface 594 to running tool slot 596. Garter springs 586 contract segments 556 radially inward. The lower shear pin 558 has been sheared by the movement of segments 556.

To continue setting or extruding seal 570, the running tool 552 is further moved upwards from its position shown in FIG. 10B. The seal 570 final setting position is shown in FIG. 10C, but in FIG. 10C the running tool 552 has already been further moved upwards from its position in FIG. 10B, and then is shown moving downwards in FIG. 10C with the drill string for drilling operations. To set the seal 570 as shown in FIG. 10C, the running tool 552 moves up from its position in FIG. 10B, and running tool shoulder 598 shoulders retainer receiving member 554 upwards until blocked by shoulder 600 of tool member 560. The ratchet or lock ring 562 allows the unidirectional upward movement of retainer receiving member 554 relative to tool member 560. Like the ratchet or lock ring 328 of FIGS. 7A-7C, ratchet or lock ring 562 resists the upward movement of the tool member 560.

Loss motion connection or groove 592 of retainer receiving member 554 allows retainer receiving member 554 to move upward until it is blocked by the third retainer 544 contacting shoulder 590 at one end of groove 592, as shown in FIG. 10C. Retainer receiving member 554 mechanically compresses and extrudes seal 570 against RCD extending member 550, which, as shown in FIG. 10A, is latchingly fixed by first retainer member 536. After the seal 570 is set with the upward movement of the running tool 552 from its position shown in FIG. 10B, inner C-ring 564 and outer segments 566 will still be concentrically disposed as shown in FIG. 10B. Running tool 552 may then be moved downward with the drill string for drilling operations. With this downward movement, running tool shoulder 588 shoulders inner C-ring 564 downwards, and outer segments 566 with their garter springs 568 will move inward into groove 572 in inner C-ring 564 in the position shown in FIG. 10C. The running tool 552 then, as described above, continues moving down out of the housing 530 for drilling operations. Ratchet or lock ring 562 resists retainer receiving member 554 from moving downwards, thereby maintaining seal assembly seal 570 extruded, as shown in FIG. 10C during the drilling operations. As can now be understood, for the embodiment shown in FIGS. 10A-10E, like the embodiment shown in FIGS. 8A-8E. and unlike the embodiments shown in FIGS. 6A-6C, 7A-7C and 9A-9E, the running tool is moved upwards for mechanically setting or extruding the seal assembly seal.

FIG. 10D shows RCD running tool 552 moving upwards into housing 532 returning upon drilling operations for the beginning of the RCD 530 retrieval process. When blocking shoulder 602 of running tool 552 shoulders inner C-ring 564, as shown in FIG. 10D, the first retainer members 536 and second retainer members 540 are preferably in their first or unlatched positions. It is also contemplated that the retainer members 536, 540 may be unlatched after the running tool 552 is in the position shown in FIG. 10D but before the position shown in FIG. 10E. Shoulder 612 of inner C-ring groove 572 shoulders outer segments 566 upward. Outer segments 566, in turn, shoulders RCD tool member 580 upwards. RCD tool member 580, in turn, moves upward until its upwardly facing blocking shoulder 608 is blocked by downwardly facing shoulder 610 of RCD extending member 550. The upward movement of RCD tool member 580, as shown in FIG. 1 OD, allows the retraction of seal assembly dog 576 into slot 606.

Turning now to FIG. 10E, running tool 552 moves further upward from its position in FIG. 10D continuing to shoulder inner C-ring 564 upward with running tool shoulder 602. Outer segments 566 continue to shoulder RCD tool member 580 so seal assembly dog 576 moves along slot 606 until contacting shoulder 604 at the end of the RCD tool member slot 606. Dog 576 may be a C-ring or other similar device with a radially inward bias. Blocking shoulder 608 of RCD tool member 580 shoulders blocking shoulder 610 of RCD extending member 550 upwards. RCD 530 having RCD extending member 550 moves upward since first retainer members 536 and second retainer members 540 are unlatched. Lip formation 574 of extending member 550 pulls and stretches seal 570 upward. Seal 570 may also be bonded with extending member 550. Retainer receiving member 554 shouldered at shoulder 590 is blocked by third retainer 544 in the latched position. It is contemplated that retainer receiving member 554 may also have a lip formation similar to formation 574 on extending member 550 and be bonded for further restraining both ends of seal 570. After seal 570 is unset or released, third retainer member 544 may be moved to its unlatched position and the running tool 552 moved upward to the surface with the RCD 530.

For all embodiments in all of the Figures, it is contemplated that the riser spool or housing with RCD disposed therein may be positioned with or adjacent the top of the riser, in any intermediate location along the length of the riser, or on or adjacent the ocean floor, such as over a conductor casing similar to shown in the '774 patent or over a BOP stack similar to shown in FIG. 4 of the '171 patent.

In FIG. 11, RCD 100′ is disposed in a single hydraulic latch assembly 240′. FIG. 11 is a cross-section view of an embodiment of a single diverter housing section, riser section, or other applicable wellbore tubular section (hereinafter a “housing section”), and a single hydraulic latch assembly to better illustrate the rotating control device 100′. As shown in FIG. 11, a latch assembly separately indicated at 210′ is bolted to a housing section 200′ with bolts 212A′ and 212B′. Although only two bolts 212A′ and 212B′ are shown in FIG. 11, any number of bolts and any desired arrangement of bolt positions can be used to provide the desired securement and sealing of the latch assembly 210′ to the housing section 200′. As shown in FIG. 11, the housing section 200′ has a single outlet 202′ for connection to a diverter conduit 204′, shown in phantom view; however, other numbers of outlets and conduits can be used with diverter conduits 115′ and 117′. Again, this conduit 204′ can be connected to a choke. The size, shape, and configuration of the housing section 200′ and latch assembly 210′ are exemplary and illustrative only, and other sizes, shapes, and configurations can be used to allow connection of the latch assembly 210′ to a riser. In addition, although the hydraulic latch assembly is shown connected to a nipple, the latch assembly can be connected to any conveniently configured section of a wellbore tubular or riser.

A landing formation 206′ of the housing section 200′ engages a shoulder 208′ of the rotating control device 100′, limiting downhole movement of the rotating control device 100′ when positioning the rotating control device 100′. The relative position of the rotating control device 100′ and housing section 200′ and latching assembly 210′ are exemplary and illustrative only, and other relative positions can be used.

FIG. 11 shows the latch assembly 210′ latched to the rotating control device 100′. A retainer member 218′ extends radially inwardly from the latch assembly 210′, engaging a latching formation 216′ in the rotating control device 100′, latching the rotating control device 100′ with the latch assembly 210′ and therefore with the housing section 200′ bolted with the latch assembly 210′. In some embodiments, the retainer member 218′ can be “C-shaped”, that can be compressed to a smaller diameter for engagement with the latching formation 216′. However, other types and shapes of retainer rings are contemplated. In other embodiments, the retainer member 218′ can be a plurality of dog, key, pin, or slip members, spaced apart and positioned around the latch assembly 210′. In embodiments where the retainer member 218′ is a plurality of dog or key members, the dog or key members can optionally be spring-biased. Although a single retainer member 218′ is described herein, a plurality of retainer members 218′ can be used. The retainer member 218′ has a cross section sufficient to engage the latching formation 216′ positively and sufficiently to limit axial movement of the rotating control device 100′ and still engage with the latch assembly 210′. An annular piston 220′ is shown in a first position in FIG. 11, in which the piston 220′ blocks the retainer member 218′ in the radially inward position for latching with the rotating control device 100′. Movement of the piston 220′ from a second position to the first position compresses or moves the retainer member 218′ radially inwardly to the engaged or latched position shown in FIG. 11. Although shown in FIG. 11 as an annular piston 220′, the piston 220′ can be implemented, for example, as a plurality of separate pistons disposed about the latch assembly 210′.

When the piston 220′ moves to a second position, the retainer member 218′ can expand or move radially outwardly to disengage from and unlatch the rotating control device 100 from the latch assembly 210′. The retainer member 218′ and latching formation 216′ can be formed such that a predetermined upward force on the rotating control device 100′ will urge the retainer member radially outwardly to unlatch the rotating control device 100′. A second or auxiliary piston 222′ can be used to urge the first piston 220′ into the second position to unlatch the rotating control device 100′, providing a backup unlatching capability. The shape and configuration of pistons 220′ and 222′ are exemplary and illustrative only, and other shapes and configurations can be used.

Hydraulic ports 232′ and 234′ and corresponding gun-drilled passageways allow hydraulic actuation of the piston 220′. Increasing the relative pressure on port 232′ causes the piston 220′ to move to the first position, latching the rotating control device 100′ to the latch assembly 210′ with the retainer member 218′. Increasing the relative pressure on port 234′ causes the piston 220′ to move to the second position, allowing the rotating control device 100′ to unlatch by allowing the retainer member 218′ to expand or move and disengage from the rotating control device 100′. Connecting hydraulic lines (not shown in the figure for clarity) to ports 232′ and 234′ allows remote actuation of the piston 220′.

The second or auxiliary annular piston 222′ is also shown as hydraulically actuated using hydraulic port 230′ and its corresponding gun-drilled passageway. Increasing the relative pressure on port 230′ causes the piston 222′ to push or urge the piston 220′ into the second or unlatched position, should direct pressure via port 234′ fail to move piston 220′ for any reason.

The hydraulic ports 230′, 232′ and 234′ and their corresponding passageways shown in FIG. 11 are exemplary and illustrative only, and other numbers and arrangements of hydraulic ports and passageways can be used. In addition, other techniques for remote actuation of pistons 220′ and 222′, other than hydraulic actuation, are contemplated for remote control of the latch assembly 210′.

Thus, the rotating control device illustrated in FIG. 11 can be positioned, latched, unlatched, and removed from the housing section 200′ and latch assembly 210′ without sending personnel below the rotary table into the moon pool to manually connect and disconnect the rotating control device 100′.

An assortment of seals is used between the various elements described herein, such as wiper seals and O-rings, known to those of ordinary skill in the art. For example, each piston 220′ preferably has an inner and outer seal to allow fluid pressure to build up and force the piston in the direction of the force. Likewise, seals can be used to seal the joints and retain the fluid from leaking between various components. In general, these seals will not be further discussed herein.

For example, seals 224A′ and 224B′ seal the rotating control device 100′ to the latch assembly 210′. Although two seals 224A′ and 224B′ are shown in FIG. 11, any number and arrangement of seals can be used. In one embodiment, seals 224A′ and 224B′ are Parker Polypak®@¼-inch cross section seals from Parker Hannifin Corporation. Other seal types can be used to provide the desired sealing.

In FIG. 12, RCD 100′ is disposed in a dual hydraulic latch assembly 300′. FIG. 12 illustrates another embodiment of a latch assembly, generally indicated at 300′, that is a dual hydraulic latch assembly. As with the single latch assembly 210′ embodiment illustrated in FIG. 11, piston 220′ compresses or moves retainer member 218′ radially inwardly to latch the rotating control device 100′ to the latch assembly 300′. The retainer member 218′ latches the rotating control device 100′ in a latching formation, shown as an annular groove 320′, in an outer housing of the rotating control device 100′ in FIG. 12. The use and shape of annular groove 320′ is exemplary and illustrative only and other latching formations and formation shapes can be used. The dual hydraulic latch assembly includes the pistons 220′ and 222′ and retainer member 218′ of the single latch assembly embodiment of FIG. 11 as a first latch subassembly. The various embodiments of the dual hydraulic latch assembly discussed below as they relate to the first latch subassembly can be equally applied to the single hydraulic latch assembly of FIG. 11.

In addition to the first latch subassembly comprising the pistons 220′ and 222′ and the retainer member 218′, the dual hydraulic latch assembly 300′ embodiment illustrated in FIG. 12 provides a second latch subassembly comprising a third piston 302′ and a second retainer member 304′. In this embodiment, the latch assembly 300′ is itself latchable to a housing section 310′, shown as a riser nipple, allowing remote positioning and removal of the latch assembly 300′. In such an embodiment, the housing section 310′ and dual hydraulic latch assembly 300′ are preferably matched with each other, with different configurations of the dual hydraulic latch assembly implemented to fit with different configurations of the housing section 310′. A common embodiment of the rotating control device 100′ can be used with multiple dual hydraulic latch assembly embodiments; alternately, different embodiments of the rotating control device 100′ can be used with each embodiment of the dual hydraulic latch assembly 300′ and housing section 310′.

As with the first latch subassembly, the piston 302′ moves to a first or latching position. However, the retainer member 304′ instead expands radially outwardly, as compared to inwardly, from the latch assembly 300′ into a latching formation 311′ in the housing section 310′. Shown in FIG. 12 as an annular groove 311′, the latching formation 311′ can be any suitable passive formation for engaging with the retainer member 304′. As with pistons 220′ and 222′, the shape and configuration of piston 302′ is exemplary and illustrative only and other shapes and configurations of piston 302′ can be used. In some embodiments, the retainer member 304′ can be “C-shaped” that can be expanded to a larger diameter for engagement with the latching formation 311′. However, other types and shapes of retainer rings are contemplated. In other embodiments, the retainer member 304′ can be a plurality of dog, key, pin, or slip members, positioned around the latch assembly 300′. In embodiments where the retainer member 304′ is a plurality of dog or key members, the dog or key members can optionally be spring-biased. Although a single retainer member 304′ is described herein, a plurality of retainer members 304′ can be used. The retainer member 304′ has a cross section sufficient to engage positively the latching formation 311′ to limit axial movement of the latch assembly 300′ and still engage with the latch assembly 300′.

Shoulder 208′ of the rotating control device 100′ in this embodiment lands on a landing formation 308′ of the latch assembly 300′, limiting downward or downhole movement of the rotating control device 100′ in the latch assembly 300′. As stated above, the latch assembly 300′ can be manufactured for use with a specific housing section, such as housing section 310′, designed to mate with the latch assembly 300′. In contrast, the latch assembly 210′ of FIG. 11 can be manufactured to standard sizes and for use with various generic housing sections 200′, which need no modification for use with the latch assembly 210′.

Cables (not shown) can be connected to eyelets or rings 322A′ and 322B′ mounted on the rotating control device 100′ to allow positioning of the rotating control device 100′ before and after installation in a latch assembly. The use of cables and eyelets for positioning and removal of the rotating control device 100′ is exemplary and illustrative, and other positioning apparatus and numbers and arrangements of eyelets or other attachment apparatus, such as discussed below, can be used.

Similarly, the latch assembly 300′ can be positioned in the housing section 310′ using cables (not shown) connected to eyelets 306A′ and 306B′, mounted on an upper surface of the latch assembly 300′. Although only two such eyelets 306A′ and 306B′ are shown in FIG. 12, other numbers and placements of eyelets can be used. Additionally, other techniques for mounting cables and other techniques for positioning the unlatched latch assembly 300′, such as discussed below, can be used. As desired by the operator of a rig, the latch assembly 300′ can be positioned or removed in the housing section 310′ with or without the rotating control device 100′. Thus, should the rotating control device 100 fail to unlatch from the latch assembly 300′ when desired, for example, the latched rotating control device 100′ and latch assembly 300′ can be unlatched from the housing section 310′ and removed as a unit for repair or replacement. In other embodiments, a shoulder of a running tool, tool joint 260A′ of a string 260′ of pipe, or any other shoulder on a tubular that could engage lower stripper rubber 246′ can be used for positioning the rotating control device 100 instead of the above-discussed eyelets and cables. An exemplary tool joint 260A′ of a string of pipe 260′ is illustrated in phantom in FIG. 11.

As best shown in FIG. 11, the rotating control device 100 includes a bearing assembly 240′. The bearing assembly 240′ is similar to the Weatherford-Williams model 7875 rotating control device, now available from Weatherford International, Inc., of Houston, Tex. Alternatively. Weatherford-Williams models 7000, 7100, IP-1000, 7800, 8000/9000, and 9200 rotating control devices or the Weatherford RPM SYSTEM 3000™, now available from Weatherford International, Inc., could be used. Preferably, a rotating control device 240′ with two spaced-apart seals, such as stripper rubbers, is used to provide redundant sealing. The major components of the bearing assembly 240′ are described in U.S. Pat. No. 5,662,181, now owned by Weatherford/Lamb, Inc., which is incorporated herein by reference in its entirety for all purposes. Generally, the bearing assembly 240′ includes a top rubber pot 242′ that is sized to receive a top stripper rubber or inner member seal 244′; however, the top rubber pot 242′ and seal 244′ can be omitted, if desired. Preferably, a bottom stripper rubber or inner member seal 246′ is connected with the top seal 244′ by the inner member of the bearing assembly 240′. The outer member of the bearing assembly 240′ is rotatably connected with the inner member. In addition, the seals 244′ and 246′ can be passive stripper rubber seals, as illustrated, or active seals as known by those of ordinary skill in the art.

In the embodiment of a single hydraulic latch assembly 210′, such as illustrated in FIG. 11, a lower accumulator may be required because hoses and lines cannot be used to maintain hydraulic fluid pressure in the bearing assembly 100′ lower portion. In addition, an accumulator allows the bearings (not shown) to be self-lubricating. An additional accumulator can be provided in the upper portion of the bearing assembly 100′ if desired.

Turning to FIG. 13, RCD 1022 is latched with housing 1020. While in operation, housing 1020 would be disposed subsea with a marine riser or directly with the wellhead or BOP stack if there were no riser. Housing 1020 has an internal latching assembly for latching the RCD 1022 or other oilfield device. First electro-hydraulic umbilical line 1024 is connected at one end with housing 1020 and may provide for the primary control for the latching assembly in housing 1020. Second electro-hydraulic umbilical line 1026 is connected at one end with a valve pack (not shown) and may also provide control for the latching assembly in housing 1020. Accumulators (1023, 1025) are removably attached to housing 1020 with accumulator clamp ring 1021. There may be four accumulators, such as shown in FIG. 21. Other numbers of accumulators are also contemplated. Returning to FIG. 13, signal device 1031 is in a stowed position below accumulators (1023, 1025). The valve pack may switch between the fluid flowing through second electro-hydraulic umbilical line 1026 and the fluid flowing from accumulators (1023, 1025), as will be discussed in detail below. Umbilical reels (1028, 1030) store respective umbilical lines (1024, 1026). Although an RCD 1022 is shown, it is contemplated that any oilfield device may be latched with the housing 1020, including, but not limited to, protective sleeves, bearing assemblies with no stripper rubbers, stripper rubbers, wireline devices, and any other oilfield devices for use with a wellbore.

In FIG. 14, acoustic control system 1007 may include surface control unit 1004, subsea control unit 1010, first acoustic signal device 1006 and second acoustic signal device 1008. A third acoustic signal device 1008A is also contemplated, as are additional acoustic signal devices. Second and third acoustic signal devices (1008, 1008A), subsea control unit 1010, and valve pack 1012 may be disposed directly with one or more operating accumulators 1016, one or more receiving accumulators or compensators 1062, on housing 1014, but are shown in exploded view in FIG. 14 for clarity. Housing 1014 contains an internal latching assembly to latch with an oilfield device, such as an RCD.

It is contemplated that the subsea components, including second and third acoustic signal devices (1008, 1008A), subsea control unit 1010, valve pack 1012, operating accumulators 1016, and receiving accumulator 1062, may be housed on a frame structure or pod around housing 1014. Second and third acoustic signal devices (1008, 1008A) may be supported on pivoting arms or extensions from the frame structure, although other attachment means are also contemplated. First signal device 1006 may be held below the water surface by reel 1005. First signal device 1006 may transmit acoustic signals as controlled by surface control unit 1004, and second acoustic device 1008 may receive the acoustic signals and transmit them to subsea control unit 1012.

First and second acoustic signal devices (1006, 1008) may be transceivers to provide for two-way communication so that both devices (1006, 1008) may transmit and receive communication signals from each other as controlled by their respective control units (1004, 1010). Devices (1006, 1008) may also be transceivers connected with transducers. Third signal device 1008A may also be a transceiver or a transceiver coupled with a transducer.

Acoustic control systems may be available from Kongsberg Maritime AS of Horten, Norway; Sonardyne Inc. of Houston, Tex.; Nautronix of Aberdeen, Scotland; and/or Oceaneering International Inc. of Houston, Tex., among others. An acoustic actuator may be used in the acoustic control system, such as is available from ORE Offshore of West Wareham, Mass., among others. It is contemplated that acoustic control system 1007 may operate in depths of up to 200 feet (61 m). It is also contemplated that acoustic signal devices (1006, 1008, 1008A) may be sonde devices. Other acoustic transmitting and receiving means as are known in the art are also contemplated. It is also contemplated that alternative optical and/or electromagnetic transmission techniques may be used.

Acoustic control system 1007 allows communication through acoustic signaling between the control unit 1004 above the surface of the water and the subsea control unit 1010. Subsea control unit 1010 may be in electrical communication or connection with valve pack 1012, which may be operable to activate one or more operating accumulators 1016 and release their stored hydraulic fluid. Operating accumulators 1016 may be pre-charged to 44 Barg, although other pressures are also contemplated. Unlike operating accumulators 1016, one or more receiving accumulators or compensators 1062 may not store pressurized hydraulic fluid for operation of the latching assembly in RCD housing 1014, but rather may receive hydraulic fluid exiting the latching assembly.

Valve pack 1012 may also be used to switch from a primary umbilical line system, such as second umbilical line 1026 in FIG. 13, to the secondary acoustic control system. It is also contemplated that the acoustic control system may be the primary system. Operating accumulators 1016 may be remotely or manually charged and/or purged, including by an ROV or diver. Although two operating accumulators 1016 are shown, it is contemplated that there may be only one operating accumulator 1016, or more than two operating accumulators 1016.

Operating accumulators 1016 and receiving accumulator 1064 are disposed with housing 1014, which may be positioned with a marine riser or otherwise with the subsea wellbore, such as with a subsea housing. An RCD or other oilfield device (not shown in FIG. 14) may be latched with the internal latching assembly in housing 1014. The housing 1014 latching assembly (not shown) may be similar to those latching assemblies shown in FIGS. 1 to 12. Housing 1014 may be disposed on a marine riser below the tension lines or tension ring. Operating accumulators 1016 may provide storage of energized hydraulic fluid to operate the latching assembly upon signal from the acoustic control system 1007. It is contemplated that bladder type accumulators may be used. Other types of accumulators are also contemplated, such as piston type. Operating accumulators 1016 may be rechargeable in their subsea position.

Using FIG. 1 for illustrative purposes, after the acoustic control system and latching system of FIG. 14 is disposed with the system of FIG. 1, operating accumulators 1016 may discharge their fluid into the latching assembly to move lower secondary piston 1000 and/or upper secondary piston 1002, and urge their respective adjacent primary pistons (14, 18) upward so as to release their respective retaining members (16, 20) and unlatch the RCD 100 from the housing 12 or marine riser 10. It is also contemplated that accumulators may be used to directly move the primary pistons (14, 18). It is also contemplated that the accumulators may be used to expand active seal 22.

Returning to FIG. 14, housing 1014 with latching assembly may have a bottom flange that may be bolted to the marine riser, subsea housing, wellhead and/or BOP stack. The housing 1014 inside profile may contain a hydraulic latch that is fabricated to receive, retain, and release the RCD or other oilfield device with locking retainer members. The housing 1014 may have lifting eyes for convenience in positioning.

Turning to FIG. 15, an exemplary configuration is shown for a secondary latch operating system and a primary umbilical line system. The secondary system may be operated using the acoustic control system 1007 of FIG. 14. Other embodiments and configurations are also contemplated. Returning to FIG. 15, operating accumulators 1016 are shown in hydraulic fluid communication with valve pack 1012. Operating accumulators 1016 may contain hydraulic fluid under pressure, such as pressurized by Nitrogen gas. Although two operating accumulators 1016 are shown, it is also contemplated that only one operating accumulator 1016 may be used. Operating accumulators 1016 may be periodically charged and/or purged. It is contemplated that a gauge may continuously monitor their pressure(s). The gauge and/or valves on the charge line may be used to charge and/or purge accumulators 1016.

Valve pack 1012 may include first valve 1040, second valve 1042 and third valve 1044, each of which may be a two-position hydraulic valve. Other types of valves are also contemplated. Valves (1040, 1042, 1044) may be controlled by a hydraulic “pilot” line 1078 that is pressurized to move the valve. It is also contemplated that a processor or PLC could control the valves (1040, 1042, 1044) using an electrical line. Remote operation is also contemplated. The valve pack 1012 may contain electric over hydraulic valves, pilot operated control valves, and manual control valves.

The subsea control unit 1010 (as shown in FIG. 14) may primarily direct the operation of the valve pack 1012 through commands sent to it from the surface control unit or console 1004. The subsea control unit 1010 may be attached at the same location as a measurement device or sensor 1064. Other locations for attachment are also contemplated. It is contemplated that measurement devices or sensors (1064, 1066, 1074, 1076) may measure temperature, pressure, flow, and/or other conditions. Sensors (1074, 1076) may be open to seawater. It is contemplated that sensors (1064, 1066) may measure hydraulic pressure and/or seawater pressure, sensor 1076 may measure seawater temperature, and sensor 1074 may measure seawater pressure. It is also contemplated that other temperatures and pressures may be measured, like well pressure.

An electro-hydraulic umbilical line, such as second electro-hydraulic line 1026 shown in FIG. 13, comprising three independent hydraulic lines may extend from the drilling rig or structure to the housing with a latching assembly and/or active seal. A first hydraulic line may be attached with first umbilical input port 1046 connected with first inner umbilical line 1046A, a second hydraulic line may be attached with second umbilical input port 1048 connected with second inner umbilical line 1048A, and a third hydraulic line may be attached with third umbilical input port 1050 connected with third inner umbilical line 1050A. The housing with latching assembly may be attached with first input port 1052, second input port 1054, and third input port 1056. First input port 1052 may be in fluid communication with the cavities or space above the primary piston(s) in the latching assembly, second input port 1054 may be in fluid communication with the cavities or space immediately below the primary piston(s) in the latching assembly, and third input port 1056 may be in fluid communication with the cavities or space below the secondary piston(s) in the latching assembly. Other configurations are also contemplated.

Using FIG. 1 for illustrative purposes, for the primary latching assembly operation, when allowed by first valve 1040, hydraulic fluid from umbilical line may move through first inner umbilical line 1046A through first input port 1052 to the latching assembly for latching or closing the latches by moving the primary pistons (14, 18) downward to the positions shown in FIG. 1. When allowed by second valve 1042, hydraulic fluid from umbilical line may move through second inner umbilical line 1048A through second input port 1054 to the latching assembly for unlatching or opening the latches by moving the primary pistons (14, 18) upward from the positions shown in FIG. 1. When allowed by third valve 1044, hydraulic fluid from umbilical line may move through third input port 1056 to the latching assembly for unlatching or opening the latches by moving the secondary pistons (1000, 1002) upward from the positions shown in FIG. 1. Operation of the secondary pistons (1000, 1002) is generally used for emergency situations when the primary pistons may not be moved.

When the umbilical line is damaged, and the secondary operating system may be required to remove a latched RCD or other oilfield device. A PLC may control valve pack 1012 to close the movement of hydraulic fluid from first, second and third inner umbilical lines (1046A, 1048A, 1050A) and open first accumulator line 1080, second accumulator line 1082, and third accumulator line 1083. As can now be understood, first, second and third valves (1040, 1042, 1044) of the valve pack 1012 may have a first and a second position. The first position may allow operation of the primary system, and the second position may allow operation of the secondary system using the acoustic control system 1007.

Check valves (1068, 1070, 1072) in the hydraulic lines allow flow in the forward direction, and prevent flow in the reverse direction. However, it is contemplated that check valves (1068, 1070, 1072) may be pilot-to-open check valves that do allow flow in the reverse direction when needed by opening the poppet. Other types of check valves are also contemplated. It is also contemplated that there may be no check valve 1072 in second accumulator line 1082.

When allowed by valve pack 1012, operating accumulators 1016 may discharge their stored charged hydraulic fluid through third accumulator line 1083 to move the secondary piston(s), such as secondary pistons (1000, 1002) in FIG. 1. Hydraulic fluid from the latch assembly displaced by the movement of the secondary pistons may move through first accumulator line 1080 and/or check valve 1068 to receiving accumulator or compensator 1062. Other paths are also contemplated. Receiving accumulator 1062, unlike operating accumulators 1016, may not contain pressurized hydraulic fluid. Rather, it may contain seawater, fresh water or other liquid and may be used to receive or catch the hydraulic fluid returns from the latching assembly to prevent their discharge into the environment or sea. It is also contemplated that, if desired, there could be no receiving accumulator 1062.

It is contemplated that the acoustic control system 1007 may be used as a back-up to the primary system, which may be one or more umbilical lines. An electro-hydraulic umbilical reel may be used to store the primary line and supply electric and hydraulic power to the RCD housing. It is also contemplated that there may also be ROV and/or human diver access for system operation. It is contemplated that the system may operate in seawater depths up to 197 feet (60 m). It is contemplated that the system may operate in temperatures ranging from 32° F. (0° C.) to 104° F. (40° C.). It is contemplated that the system opening pressure may be 700 psi (48 bar) or greater when performing an unlatching operation. It is contemplated that the system opening pressure may not exceed 1200 psi (83 bar) when performing an unlatching operation.

It is contemplated that the system flow rate may not be more than 10 gpm (381 pm) or greater when performing an unlatching operation. It is contemplated that the system flow rate may be 0.75 gpm (2.81 bar) or greater to fully unlatch the primary and secondary latches. It is contemplated that system flow volume may be between 0.75 gallons (2.84 liters) and 1.35 gallons (5.11 liters) to unlatch (open) the primary and secondary latches at least once. The operating accumulators 1016 may be rechargeable in their subsea positions. It is contemplated that the system be operable with Weatherford Model 7878 BTR. As alternative embodiments, instead of operating accumulators 1016, or in addition to them, a self contained power source, such as electrical, hydraulic, radio control, or other type, may be used so that when remotely signaled it would release stored energy to cause the primary and secondary unlock circuits of the latching assembly to function.

It is contemplated that fluid returns from the latching assembly when operating with the acoustic control system and latch operating system shown in FIGS. 14 and 15 would not be ejected into the environment, but captured. It is contemplated that a monitoring gauge may be attached with the charge line of the operating accumulators 1016, such as to monitor pressure. The gauge may be used to add or remove hydraulic fluid and to increase or decrease pressure. There may be valves about the accumulator charge line connection and gauge to permit manual charging or purging of the system. The system may be easily attached with the housing.

FIGS. 16 to 18 show some of the environments in which the acoustic control system 1007 and latch operating system of FIGS. 13-15 may be used. Other environments are also contemplated. In FIG. 16, floating drilling rig or structure S is disposed over wellhead W. Subsea BOP stack BOPS is disposed on wellhead W, and marine riser R with gas handler annular BOP GH extends between the BOPS and rig S. Tension lines T are attached with the slip joint SJ near the top of the riser R with a tensioner ring (not shown). A diverter D is below the rig floor F.

Acoustic control system 1007 is positioned with structure S and riser R. An RCD or other oilfield device (not shown) may be latched within housing 1014 positioned with riser R below tension lines T and tension ring adjacent the location of the gas handler annular BOP GH. It is contemplated than a housing 1014 with latched RCD or other oilfield device may be disposed with a frame structure or pod supporting valve pack 1012, accumulators (1016, 1062), subsea control unit 1010, and subsea signal devices (1008, 1008A). Surface equipment including surface control unit 1004, reel 1005, and signal device 1006 may be supported from the rig S.

In FIG. 17, RCD 38A is disposed with a subsea housing SH at the sea floor SF and disposed with the subsea wellhead W. Subsea housing SH and RCD 38A allow for subsea drilling with no marine riser. In FIG. 18. RCD 38A is disposed with a subsea housing SH1 disposed over subsea BOP stack BOPS. Subsea housing SH1 and RCD 38A allow for subsea drilling with no marine riser. The acoustic control system 1007 and latch operating system as shown in FIGS. 13-16 may be disposed with the subsea housings (SH, SH1) of FIGS. 17 and 18 and used for operating a latch assembly for latching and unlatching the RCD 38A and/or for expanding and decreasing an active seal. It is contemplated that the components of the system may be supported on a frame structure or pod.

Turning to FIG. 19, an RCD 1102 is latched with housing 1100. Although an RCD 1102 is shown, it is contemplated that any oilfield device may be latched with the housing 1100. While in operation, housing 1100 would be disposed subsea with a marine riser or directly with the wellhead or BOP stack if there were no riser. Housing 1100 has an internal latching assembly for latching the RCD 1102 or other oilfield device. Accumulators (1106, 1108) are removably attached to housing 1100 with accumulator clamp ring 1104. There may be four accumulators, such as shown in FIG. 21. As discussed above, other numbers of accumulators are contemplated. Returning to FIG. 19, signal device 1110 is in a stowed position below accumulators (1106, 1108). Accumulators may store a fluid for operation of the internal latching assembly of the housing 1100. In FIG. 20, signal device 1110 has been moved to a deployed position.

In FIG. 21, three operating accumulators (1106, 1108, 1112) are provided for releasing hydraulic fluid to the latching assembly, as discussed above, in housing 1100. A receiving accumulator or compensator 1114 is for receiving hydraulic fluid from the latching assembly in housing 1100. The accumulators (1106, 1108, 1112, 1114) are attached to housing 1100 using accumulator clamp ring 1104. As shown in FIG. 22, the signal device (1110, 1110A) is movable by pivoting from a stowed position (in phantom view) to a deployed position.

Turning to FIGS. 23A-23B, an exemplary configuration is shown for a secondary latch operating system and a primary umbilical line system. The secondary system may be operated with acoustic control system 1007. Other embodiments and configurations are also contemplated. Operating accumulators (1120, 1122, 1124) are shown in hydraulic fluid communication with manifold or valve pack 1128. Operating accumulators (1120, 1122, 1124) may contain hydraulic fluid under pressure, such as pressurized by Nitrogen gas. Although three operating accumulators are shown in FIGS. 21-23A, it is also contemplated that only one operating accumulator could be used. Operating accumulators may be periodically charged and/or purged. It is contemplated that a gauge may continuously monitor their pressure(s). The gauge and/or valves on the charge line may be used to charge and/or purge accumulators. Accumulator or compensator 1126 may be used to received hydraulic fluid as discussed above.

Manifold or valve pack 1128 may include first valve 1130, second valve 1132 and third valve 1134, each of which may be two-position hydraulic valves. Other types of valves are also contemplated. Valves (1130, 1132, 1134) may be controlled by a hydraulic “pilot” line 1136 that is pressurized to move the respective valve. As best shown in FIG. 23B, the acoustic control system 1007 may use an electric over hydraulic control over valves (1130, 1132, 1134). The valves (1160, 1162, 1164) control the function of both switching from the primary umbilical line system to the secondary latch operating system and performing the emergency unlatch operation by the secondary latch operating system. Valves (1160, 1162) may be electrically controlled by subsea control units (SCU) (1136, 1138) as shown in FIG. 23A. Valve 1164 is pilot-operated by valve 1162.

In particular, activation of valve 1164 will pilot-operate and switch valves (1130, 1132, 1134) from the primary umbilical line system to the secondary latch operating system. This switching allows the emergency unlatching of the latching assembly where valve 1164 is activated by the pilot-operated control valve 1162. Activation of valve 1164 allows pressurized hydraulic fluid from the accumulator(s) (1120, 1122, 1124) to unlatch the RCD or other oilfield device from the housing using the secondary latch operating system. The accumulators (1120, 1122, 1124) may be 10-liter subsea bladder accumulators with a seal subfluid connection, ¼″ BSPM gas connection, a C/W lifting eye bolt, SCHRADER valve and cushion ring. Compensator 1126 may be a 10-liter subsea compensator being internally nickel-plated ½″ BSP hydraulic fluid connection open seawater connection 207 BARG design pressure and C/W cushion ring. A valve 1166 may be a ⅜″ NB subsea manual needle valve C/W ½″ OD×0.65″ WT 38 mm long tube tail. Coupler 168 may be a ⅜″ NB male flange mounted mono coupler universal un-vented C/W 1000 mm tube tail ½″×0.065″ WT. Coupler 1170 may be a ⅜″ NB female mono coupler universal (un-vented) C/W JIC #8 CHEMRAS seals. Couplings 1172 may be a ¼″ NB female stabplate mounted hydraulic coupling universal C/W 17 mm seal-sub back end ¼″ UNC holes un-vented. Couplings 1174 may be ¼″ NB stabplate mounted male “reduced forge” hydraulic couplings universal #8 JIC un-vented. The valves 1130, 1132 and 1134 may be 2-position, 3-way normally open poppet valve. Valve 1164 may be a 2-position, 2-way normally closed poppet valve. Valves 1160 and 1162 may be 2-position, 3-way normally closed 24 volt DC solenoid valve C/W 3 m RAYCHEM Fyling leads. Sensor 1146 may be a ¼″ BSP manifold-mounted pressure transducer, 0-1000 BARG. Transducer 1144 could be a ¼″ BSP manifold-mounted temperature transducer (seawater temp). Ports 1154, 1156 and 1158 could include a ¼″ stabplate coupling male, 569 BARG ½″×0.065″ WT×1000 mm tube tail. It is also contemplated that a processor or PLC could control the valves (1130, 1132, 1134) using an electrical line. Remote operation is also contemplated. The valve pack 1128 may contain electric over hydraulic valves, pilot operated control valves, and/or manual control valves.

Subsea control units (1136, 1138) may primarily direct the operation of the valve pack 1128 through commands sent to the subsea control units from a surface control unit or console, such as unit 1004 shown in FIGS. 14 and 16. The subsea control units (1136, 1138) may be attached at the same location as measurement device or sensor 1140. Other locations for attachment are also contemplated. Measurement devices or sensors (1140, 1142, 1144, 1146) may measure temperature, pressure, flow, and/or other conditions. Sensors (1144, 1146) may be open to seawater. It is contemplated that sensors (1140, 1142) may measure hydraulic pressure and/or seawater pressure, sensor 1146 may measure seawater temperature, and sensor 1144 may measure seawater pressure. It is also contemplated that other temperatures and pressures may be measured, like well pressure.

An electro-hydraulic umbilical line, such as second electro-hydraulic line 1026, shown in FIG. 13, containing three independent hydraulic lines may extend from the drilling rig or structure to the housing with a latching assembly or active seal. Referring to both FIGS. 23A and 23B, a first hydraulic line may be attached with first umbilical input port 1148 connected with first inner umbilical line 1148A, a second hydraulic line may be attached with second umbilical input port 1150 connected with second inner umbilical line 1150A, and a third hydraulic line may be attached with third umbilical input port 1152 connected with third inner umbilical line 1152A. The housing with latching assembly may be attached with first input port 1154, second input port 1156, and third input port 1158. First input port 1154 may be in fluid communication with the cavities or space above the primary pistons in the latching assembly, second input port 1156 may be in fluid communication with the cavities or space immediately below the primary pistons in the latching assembly, and third input port 1158 may be in fluid communication with the cavities or space below the secondary pistons in the latching assembly. Other configurations are also contemplated.

As can now be understood, the system may monitor seawater temperature and pressure and stored hydraulic supply and return pressure. The system also provides the ability to remotely control the open and close valves and provides enough stored volume in the accumulators to operate the emergency unlatching in the event of a primary and secondary latch hydraulic failure. The design of the control system may be based on two acoustic subsea control units (SCUs) mounted on the housing that will receive signals from the topside acoustic command unit and operate the directional control valves. The two acoustic subsea control units will also send signals, such as 4-20 mA signals, to the topside acoustic control unit. As best shown in FIG. 23A, two acoustic subsea control units (SCUs) (1136, 1138) may be used but it should be understood that only one SCU may be used to implement the function of the acoustic control system 1007. The design of the system may offer, among other things, (1) a redundant subsea system with two complete sets of electronics with separate replaceable batteries, (2) high availability and reliability based on equipment selection, design principles, (3) low electrical power consumption, and (4) low maintenance.

It is contemplated that the system may operate in seawater up to 197 feet (60 meters) below the surface. The system may operate in a temperature range from 32° F. (0° C.) to 104° F. (40° C.). The system opening pressure may be 700 psi (48 bar) or greater when performing an emergency unlatching (open) operation. The system opening pressure may not exceed 1200 psi (83 bar) when performing an emergency unlatching (open) operation. The system flow rate may not exceed 0.75 gpm (2.81 bar) when performing an emergency unlatching (open) operation. The system flow volume may be between 0.75 gallons (2.84 liters) and 1.35 gallons (5.11 liters) to fully unlatch (open) the primary and the secondary latch pistons.

The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the details of the illustrated apparatus and system, and the construction and the method of operation may be made without departing from the spirit of the invention. 

1-45. (canceled)
 46. A method of data transmission from a subsea housing, the method comprising: receiving data at a remote operated vehicle (ROV) panel with the subsea housing, wherein the data is selected from the group consisting of: a) a pressure in the housing, b) a temperature in the housing, c) a flow of fluid in the housing and d) a position of a latching piston in the housing; and communicating the data from the ROV panel to a subsea ROV.
 47. A method, comprising: outputting from a sensor a data signal indicative of a well parameter; wirelessly transmitting the data signal to a location selected from the group consisting of a subsea location and a surface location; and processing the data signal at the location.
 48. The method of claim 46, further comprising transmitting a hydraulic fluid from the subsea ROV to the ROV panel.
 49. The method of claim 46, further comprising transmitting a signal wirelessly from the subsea ROV to the ROV panel.
 50. The method of claim 46, wherein the communicating comprises transmitting a signal wirelessly from the ROV panel to the subsea ROV.
 51. The method of claim 46, wherein the communicating comprises acoustically transmitting the data.
 52. The method of claim 46, further comprising processing the data at a subsea location.
 53. The method of claim 52, wherein the subsea location is in the subsea ROV.
 54. The method of claim 46, further comprising processing the data at a surface location.
 55. The method of claim 47, wherein the well parameter is selected from the group consisting of: a) a pressure in a subsea housing, b) a temperature in the housing, c) a flow of fluid in the housing and d) a position of a latching piston in the housing.
 56. The method of claim 55, further comprising positioning an oilfield device at least partially in the subsea housing.
 57. The method of claim 56, wherein the oilfield device comprises a rotating control device.
 58. The method of claim 47, wherein the wirelessly transmitting further comprises acoustically transmitting the data signal.
 59. The method of claim 47, wherein the location comprises a subsea remote operated vehicle.
 60. The method of claim 47, further comprising wirelessly transmitting to a signal device with a subsea housing.
 61. The method of claim 60, wherein the wirelessly transmitting comprises acoustically transmitting.
 62. The method of claim 60, further comprising positioning an oilfield device at least partially in the subsea housing.
 63. The method of claim 62, wherein the oilfield device comprises a rotating control device. 